Lightweight charging cable for high-voltage fast charging

Abstract

The invention relates to the technical field of cables, in particular to a light-weight charging cable for high-voltage fast charging, which comprises a cable body, the cable body comprises a cable core and an outer wrapping layer wrapping the cable core, a liquid cooling assembly is arranged between the cable core and the outer wrapping layer, and the liquid cooling assembly comprises a circular ring sleeving the cable core. The circular rings are arranged at intervals in the length direction of the cable body, annular cavities are formed in the circular rings, liquid cooling pipes are arranged between the adjacent circular rings, the two ends of each liquid cooling pipe are communicated with the annular cavities, sliding blocks are slidably connected in the annular cavities and occupy half of the space in the annular cavities, one side of one circular ring is communicated with a liquid inlet pipe, and the cable core comprises an inner-layer wire harness and an outer-layer wire harness. The technical problems that according to an existing cable liquid cooling heat dissipation mode, the temperature difference of the contact position of cooling liquid and a cable is small, the speed of transferring heat to the cooling liquid through the cable is low, consequently, the heat dissipation speed of the cable is reduced, and meanwhile the working power consumption of a pump is increased due to the increased heat dissipation time are solved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to a lightweight charging cable for high-voltage fast charging. Background Technology

[0002] Electric vehicles require high-voltage fast charging harnesses during charging. These harnesses facilitate installation and maintenance, ensuring that electrical equipment can operate under the most severe conditions. They combine wires of different specifications and colors used by various electrical devices in the vehicle into a single unit through reasonable arrangement and bundle them together with insulating material. High-voltage fast charging cables need to withstand large currents under high voltage to achieve high power. The higher the current, the higher the heat generated by the conductor resistance. Therefore, the heat dissipation capacity of the cable is crucial.

[0003] To improve the heat dissipation capacity of cables and reduce their weight, high-voltage fast charging cables are increasingly adopting liquid cooling. This involves integrating tiny cooling pipes filled with a special insulating coolant inside the cable. An external pump and radiator allow the coolant to circulate within the cable, directly carrying away the heat generated by the conductor. The cooling process relies solely on heat transfer from the cable to the cooling pipes, and then from the cooling pipes to the coolant. However, the continuous heat loss from the cooling pipes reduces their own heat level, slowing down the heat transfer from the cable to the coolant. This results in the coolant carrying away only a small amount of heat, not only slowing down the heat dissipation process but also increasing the pump's power consumption. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a lightweight charging cable for high-voltage fast charging. It solves the technical problem that existing liquid cooling methods for cables result in a small temperature difference between the coolant and the cable at the contact point, leading to a slow heat transfer rate from the cable to the coolant, which in turn slows down the heat dissipation of the cable and increases the power consumption of the pump due to the extended heat dissipation time.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: A lightweight charging cable for high-voltage fast charging includes a cable body, the cable body including a cable core and an outer sheath layer that wraps the cable core, and a liquid cooling component is provided between the cable core and the outer sheath layer; The liquid cooling assembly includes a ring sleeved around the outside of the cable core. The rings are spaced apart along the length of the cable body. An annular cavity is formed inside the ring. A liquid cooling pipe is provided between adjacent rings. Both ends of the liquid cooling pipe are connected to the annular cavity. A slider is slidably connected inside the annular cavity. The slider occupies half of the space inside the annular cavity. One side of one of the rings is connected to a liquid inlet pipe.

[0006] Furthermore, the cable core includes an inner wire harness and an outer wire harness, and the annulus is provided with a filler layer filling the space between the inner wire harness and the outer wire harness.

[0007] Furthermore, the cable core is fitted with a collar that fits the circular ring, and an elastic sheet is fixedly connected between the collar and the circular ring.

[0008] Furthermore, the slider is made of lightweight rubber and has a cavity inside.

[0009] Furthermore, one end of the slider is connected to an arc-shaped plate with the opening of the arc-shaped plate facing the slider. The arc-shaped plate is made of an elastic material, and a swing plate is rotatably connected between the arc-shaped plate and the slider.

[0010] Furthermore, a traction rope is provided between adjacent rings, and a winding assembly for winding the traction rope is provided on one side of the ring.

[0011] Furthermore, the winding assembly includes a winding rod corresponding to the traction rope, a groove for accommodating the winding rod is provided on the outer side of the ring, a torsion spring is fixedly connected between one end of the winding rod and the ring, and one end of the traction rope is fixed to the winding rod.

[0012] Furthermore, a lifting block is slidably connected to the inner wall of the groove, and a semi-circular groove adapted to the winding rod is opened at the bottom of the lifting block. A spring is fixedly connected between the lifting block and the ring, and a protrusion is fixedly connected to the side of the spring away from the spring, with the protrusion extending to the outside of the ring.

[0013] Furthermore, a thermally conductive pad is provided between the liquid cooling pipe and the cable core. The thermally conductive pad has pleats, and both ends of the thermally conductive pad are fixed to a circular ring.

[0014] By employing the above technical solution, the present invention provides a lightweight charging cable for high-voltage fast charging, which has at least the following beneficial effects: 1. The present invention, through the liquid cooling component, can utilize the flow of coolant to alternate between two states: blocked and unblocked. When the liquid cooling pipe is blocked, it continuously absorbs heat from the cable, increasing the temperature difference between the liquid cooling pipe and the coolant. When the liquid cooling pipe is unblocked, it transfers the heat from the liquid cooling pipe to the coolant, which is then carried away. With the same coolant flow rate, it can increase the temperature difference at the contact point between the coolant and the cable, accelerate the transfer of heat from the cable to the coolant, and speed up the heat dissipation of the cable. At the same time, the reduced heat dissipation time also reduces the power consumption of the delivery pump.

[0015] 2. The present invention increases the external protective structure of the cable by setting the ring, collar and elastic sheet, and improves the buffering capacity of the cable when it is impacted by external force, which can reduce the possibility of cable core damage when the cable is impacted.

[0016] 3. The present invention, through the setting of the arc plate, can use the support of the inner wall of the annular cavity to block the coolant from impacting one end of the slider, so that the flowing coolant can only push the slider to move in one direction, preventing the coolant from impacting the slider from both sides at the same time, which would prevent the slider from being pushed. It can ensure that the slider always moves in one direction after being impacted by the coolant.

[0017] 4. The present invention, through the setting of the winding component, lifting block, spring and protrusion, can conveniently adjust the spacing of the rings on the cable body as needed, and automatically fix the traction rope when the cable core is wrapped with the outer layer, so that the traction rope cannot be stretched further, thereby preventing the spacing of the rings from increasing further. The cable's resistance to external impacts can be adjusted according to the tightness of the ring distribution.

[0018] 5. The present invention uses a pleated thermally conductive pad to increase the contact area between the pad and the cable body by widening the spacing of the circular distribution on the cable. This accelerates the transfer of heat from the cable to the liquid cooling pipe, thereby speeding up the heat dissipation of the cable. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the cable body of the present invention; Figure 2 This is a partial structural diagram of the cable body of the present invention; Figure 3 This is a schematic diagram of the cable core and liquid cooling assembly of the present invention; Figure 4 This is an internal cross-sectional view of the liquid cooling component of the present invention; Figure 5 This is a cross-sectional view of the liquid cooling assembly of the present invention; Figure 6 This is a partial cross-sectional view of the slider of the present invention; Figure 7 This is a schematic diagram of the structure of the traction rope and winding assembly of the present invention.

[0020] In the diagram: 100, Cable body; 1, Cable core; 2, Outer sheath; 3, Liquid cooling assembly; 31, Ring; 32, Annular cavity; 33, Liquid cooling pipe; 34, Slider; 35, Liquid inlet pipe; 4, Filler layer; 5, Collar; 6, Elastic sheet; 7, Cavity; 8, Arc plate; 9, Swing plate; 10, Traction rope; 11, Rewinding assembly; 111, Rewinding rod; 112, Torsion spring; 12, Lifting block; 13, Spring; 14, Protrusion; 15, Thermal pad. Detailed Implementation

[0021] The technical solutions of 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.

[0022] Example 1 To increase the temperature difference between the coolant and the cable contact point, thereby accelerating the transfer of heat generated by the cable to the coolant and thus speeding up heat dissipation from the cable, please refer to... Figures 1-5 This embodiment proposes a lightweight charging cable for high-voltage fast charging, including a cable body 100. The cable body 100 includes a cable core 1 and an outer sheath 2 that wraps around the cable core 1. A liquid cooling assembly 3 is provided between the cable core 1 and the outer sheath 2. The liquid cooling assembly 3 includes a ring 31 that is sleeved on the outside of the cable core 1. The rings 31 are spaced apart along the length of the cable body 100. An annular cavity 32 is opened in the ring 31. A liquid cooling pipe 33 is provided between adjacent rings 31. Both ends of the liquid cooling pipe 33 are connected to the annular cavity 32. A slider 34 is slidably connected in the annular cavity 32. The slider 34 occupies half of the space in the annular cavity 32. One side of one of the rings 31 is connected to a liquid inlet pipe 35.

[0023] In use, the inlet pipe 35 is connected to a delivery pump to deliver coolant into the inlet pipe 35. The coolant in the inlet pipe 35 flows into the annular cavity 32 of the ring 31. On one hand, it enters the liquid cooling pipe 33 through the annular cavity 32 and moves continuously along the direction of the cable body 100. On the other hand, it pushes the slider 34 to slide along the annular cavity 32, blocking the liquid cooling pipe 33 at different positions, so that the liquid cooling pipe 33 alternates between being blocked and not blocked. The specific process is as follows: When the liquid cooling pipe 33 is blocked, the coolant does not flow through it. Instead, the pipe is wrapped by the cable, which heats up when current flows through it. The cable's heat is transferred to the pipe, continuously heating it. This continuous heating, achieved while the pipe is blocked, increases the temperature difference between the pipe and the coolant. When the pipe is not blocked, the coolant in the annular cavity 32 flows into it. The heat from the pipe is transferred to the coolant, which then carries the coolant along the length of the cable body 100 until the coolant flows out of the electrical outlet. After the cable body 100 is cooled down, the cooled coolant is then pumped back into the inlet pipe 35. This process is repeated, allowing the coolant flow to alternate between blocked and unblocked states in the liquid cooling pipe 33. When the liquid cooling pipe 33 is blocked, it continuously absorbs heat from the cable, increasing the temperature difference between the liquid cooling pipe 33 and the coolant. When the liquid cooling pipe 33 is unblocked, the heat on the liquid cooling pipe 33 is transferred to the coolant and carried away. With the same coolant flow rate, this increases the temperature difference at the contact point between the coolant and the cable, accelerating the transfer of heat from the cable to the coolant and speeding up the heat dissipation of the cable. The reduced heat dissipation time also reduces the power consumption of the pump.

[0024] To enhance the cable's strength and enable it to better withstand external impacts, refer to... Figure 2 , Figure 3 and Figure 4 The cable core 1 includes an inner wire harness and an outer wire harness. The ring 31 is provided with a filling layer 4 between the inner wire harness and the outer wire harness. The cable core 1 is fitted with a collar 5 that is compatible with the ring 31. An elastic piece 6 is fixedly connected between the collar 5 and the ring 31.

[0025] When the cable is subjected to external impact, the external force first impacts the outer sheath and is then blocked by the ring 31. The ring 31 protects the cable outside the cable core 1 and enhances the cable's strength. When the ring 31 is impacted, it pushes the collar 5 through the elastic sheet 6. The collar 5 forms a second protective layer outside the cable core 1. The elastic sheet 6 can bend to buffer when impacted, increasing the external protective structure of the cable and improving the cable's buffering capacity when impacted by external forces, thus reducing the possibility of damage to the cable core when the cable is impacted.

[0026] Example 2 To prevent slider 34 from being simultaneously pushed from both sides by liquid cooling and becoming immobile, refer to... Figures 1-6 Based on Embodiment 1, the slider 34 is made of lightweight rubber, and a cavity 7 is provided inside the slider 34. An arc plate 8 is connected to one end of the slider 34. The opening of the arc plate 8 faces the slider 34. The length of the arc plate 8 exceeds the width of the annular cavity 32. The arc plate 8 is made of elastic material. A swing plate 9 is rotatably connected between the arc plate 8 and the slider 34.

[0027] In use, the curved plate 8, due to its own elasticity, presses against the inner wall of the annular cavity 32 at both ends, as shown in the reference. Figure 5 and Figure 6 The coolant flowing from the liquid cooling pipe 33 into the left side of the annular cavity 32 is first blocked by the arc plate 8. Because the arc plate 8 is stuck by the inner wall of the annular cavity 32 and cannot move counterclockwise, the coolant flowing into the left side of the annular cavity 32 cannot transmit the impact force to the slider 34. The coolant flowing from the liquid cooling pipe 33 into the right side of the annular cavity 32 directly impacts the slider 34, pushing the slider 34 to rotate clockwise. After the slider 34 moves, it pushes the arc plate 8 through the swing plate 9. The arc plate 8 is not stuck by the inner wall of the annular cavity 32 when it moves clockwise, so it can move smoothly in the clockwise direction. It can use the support of the inner wall of the annular cavity 32 to block the coolant from impacting one end of the slider 34, so that the flowing coolant can only push the slider 34 to move in one direction. It prevents the coolant from impacting the slider 34 from both sides at the same time, which would prevent the slider 34 from being pushed. It can ensure that the slider 34 always moves in one direction after being impacted by the coolant.

[0028] Example 3 In order to flexibly adjust the spacing of the rings 31 on the cable body 100 as needed, refer to Figures 1-7 Based on Embodiment 1, a traction rope 10 is provided between adjacent rings 31. A winding assembly 11 for winding the traction rope 10 is provided on one side of the ring 31. The winding assembly 11 includes a winding rod 111 corresponding to the traction rope 10. A groove for accommodating the winding rod 111 is provided on the outer side of the ring 31. A torsion spring 112 is fixedly connected between one end of the winding rod 111 and the ring 31. One end of the traction rope 10 is fixed on the winding rod 111. A lifting block 12 is slidably connected to the inner wall of the groove. A semi-circular groove adapted to the winding rod 111 is provided at the bottom of the lifting block 12. A spring 13 is fixedly connected between the lifting block 12 and the ring 31. A protrusion 14 is fixedly connected on the side of the spring 13 away from the spring 13. The protrusion 14 extends to the outside of the ring 31.

[0029] In use, the ring 31 is placed around the outside of the cable core 1, and then the ring 31 is moved along the cable core 1 until the distance between the rings 31 meets the requirements. Then, a liquid cooling tube 33 of appropriate length is fixed between two adjacent rings 31, so that the liquid cooling tube 33 and the annular cavity 32 are connected. During the movement of the ring 31, the ring 31 drives the traction rope 10 to move, pulling out the traction rope 10 wound on the winding rod 111. As the traction rope 10 drives the winding rod 111 to rotate, the winding rod 111 causes the torsion spring 112 to twist and deform. Finally, the outer sheath 2 is wrapped around the outside of the cable core 1 and the ring 31. The outer sheath 2 squeezes the ring 31 inward, extending to the annular cavity 32. The protrusion 14 on the outside of ring 31 is pressed into the ring 31. The protrusion 14 pushes the lifting block 12 to press the winding rod 111, pressing and fixing the traction rope 10 on the winding rod 111, so that the traction rope 10 on the winding rod 111 cannot be pulled out further. When the lifting block 12 moves, it compresses the spring 13, which can easily adjust the spacing of the rings 31 on the cable body 100 as needed. When the cable core 1 is wrapped with the outer sheath 2, the traction rope 10 is automatically fixed, so that the traction rope 10 cannot be stretched further, thus preventing the spacing of the rings 31 from increasing further. The cable's resistance to external impact is adjusted according to the tightness of the rings 31 distribution.

[0030] In order to improve the heat dissipation capacity of the cable after the distribution spacing of the ring 31 is increased, refer to Figure 3 A heat-conducting pad 15 is provided between the liquid cooling pipe 33 and the cable core 1. The heat-conducting pad 15 has pleats, and both ends of the heat-conducting pad 15 are fixed to the ring 31.

[0031] As the spacing between the rings 31 increases, the rings 31 pull the thermal pad 15 to elongate, reducing the bending degree of the thermal pad 15. As the distance between the rings 31 increases, the thermal pad 15 is gradually stretched to a flat state. When the cable body 100 bends, it can squeeze the thermal pad 15 to wrap around the liquid cooling pipe 33 from the side. When the thermal pad 15 is obviously wrinkled, it is squeezed tightly against the liquid cooling pipe 33. Due to the presence of wrinkles, the contact area between the thermal pad 15 and the liquid cooling pipe 33 is also small. After the spacing of the rings 31 on the cable increases, the thermal pad 15 is used to increase the contact area with the cable body 100, thereby accelerating the transfer of heat from the cable to the liquid cooling pipe 33 through the thermal pad 15, thus achieving the purpose of accelerating heat dissipation of the cable.

[0032] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0033] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A lightweight charging cable for high-voltage fast charging, comprising a cable body (100), said cable body (100) comprising a cable core (1) and an outer sheath (2) wrapping the cable core (1), characterized in that, A liquid cooling assembly (3) is provided between the cable core (1) and the outer sheath (2). The liquid cooling assembly (3) includes a ring (31) sleeved on the outside of the cable core (1). The rings (31) are spaced apart along the length of the cable body (100). An annular cavity (32) is opened in the ring (31). A liquid cooling pipe (33) is provided between adjacent rings (31). Both ends of the liquid cooling pipe (33) are connected to the annular cavity (32). A slider (34) is slidably connected in the annular cavity (32). The slider (34) occupies half of the space in the annular cavity (32). One side of one of the rings (31) is connected to a liquid inlet pipe (35).

2. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, The cable core (1) includes an inner wire harness and an outer wire harness, and the ring (31) is provided with a filling layer (4) between the inner wire harness and the outer wire harness.

3. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, The cable core (1) is fitted with a collar (5) that is compatible with the ring (31), and an elastic sheet (6) is fixedly connected between the collar (5) and the ring (31).

4. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, The slider (34) is made of lightweight rubber and has a cavity (7) inside.

5. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, One end of the slider (34) is connected to an arc plate (8), the arc plate (8) has an opening facing the slider (34), the arc plate (8) is made of elastic material, and a swing plate (9) is rotatably connected between the arc plate (8) and the slider (34).

6. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, A traction rope (10) is provided between adjacent rings (31), and a winding assembly (11) for winding the traction rope (10) is provided on one side of the ring (31).

7. The lightweight charging cable for high-voltage fast charging according to claim 6, characterized in that, The winding assembly (11) includes a winding rod (111) corresponding to the traction rope (10). A groove for accommodating the winding rod (111) is provided on the outer side of the ring (31). A torsion spring (112) is fixedly connected between one end of the winding rod (111) and the ring (31). One end of the traction rope (10) is fixed on the winding rod (111).

8. The lightweight charging cable for high-voltage fast charging according to claim 7, characterized in that, A lifting block (12) is slidably connected to the inner wall of the groove. The bottom of the lifting block (12) is provided with a semi-circular groove that is compatible with the winding rod (111). A spring (13) is fixedly connected between the lifting block (12) and the ring (31). A protrusion (14) is fixedly connected to the side of the spring (13) away from the spring (13). The protrusion (14) extends to the outside of the ring (31).

9. The lightweight charging cable for high-voltage fast charging according to claim 1, characterized in that, A heat-conducting pad (15) is provided between the liquid cooling pipe (33) and the cable core (1). The heat-conducting pad (15) has pleats, and both ends of the heat-conducting pad (15) are fixed to the ring (31).

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