Liquid cooling charging wire and preparation method thereof

Abstract

The invention discloses a liquid cooling charging wire and a preparation method thereof, the liquid cooling charging wire comprises a liquid cooling lead, a cooling pipe, a signal line group, an inner protection layer and a protection layer, the inner protection layer wraps the outer sides of the liquid cooling lead, the cooling pipe and the signal line group, and the protection layer wraps the outer side of the inner protection layer; the liquid cooling wire comprises a conductor and an insulating layer wrapping the outer side of the conductor, the conductor is formed by mixing a copper material and an aerogel material, the conductor is of a hollow structure, and a liquid cooling pipe is inserted into the conductor. The liquid cooling pipe and the conductor are assembled together, so that the size of the cable is reduced, breakage caused by bending of the cable is avoided, and the stability of the new energy high-power charging cable is ensured.

Description

Technical Field

[0001] This invention relates to wire structure, and more particularly to a liquid-cooled charging wire and its preparation method. Background Technology

[0002] The development of new energy electric vehicles is rapid, with their market share increasing year by year. This has led to a corresponding increase in demand for charging stations and, at the same time, higher requirements for charging efficiency. High-power charging effectively shortens charging waiting time, reduces anxiety about charging and range, and increases charging power by improving the current-carrying capacity of the wires.

[0003] It is said that increasing the current carrying capacity by upgrading the conductor specifications results in heavier cables, making them inconvenient to use and significantly increasing costs, which is not conducive to market development. Increasing the outer diameter of the wires leads to severe twisting and turning, and a shorter lifespan under dynamic use. Summary of the Invention

[0004] This invention overcomes the shortcomings of the prior art and provides a liquid-cooled charging cable and its preparation method.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A liquid-cooled charging cable includes a liquid-cooled conductor, a cooling pipe, a signal line group, an inner sheath, and a protective layer. The inner sheath wraps around the liquid-cooled conductor, the cooling pipe, and the signal line group, and the protective layer wraps around the outer side of the inner sheath. The liquid-cooled wire includes a conductor and an insulating layer wrapped around the outside of the conductor. The conductor is made of a mixture of copper and aerogel materials and has a hollow structure. A liquid-cooled tube is inserted inside the conductor.

[0006] More specifically, the aerogel material is configured as a metal aerogel, and the preparation process of the metal aerogel material includes: S1, a solution of copper hydroxide metal salt is mixed with a reducing agent to form a solution of metal nanoparticles; S2, an initiator is added to the metal nanoparticle solution to form a self-supporting wet gel; S3, the self-supporting wet gel is dried and shaped using freeze-drying to form a metal aerogel.

[0007] More specifically, the reducing agent is sodium borohydride or sodium citrate.

[0008] More specifically, when the molar ratio of reducing agent to metal is less than or equal to 50, ligands are added to the metal nanoparticles.

[0009] More specifically, the ligand is set as sodium citrate or polyvinylpyrrolidone.

[0010] More specifically, the initiator is configured as a salt initiator.

[0011] More specifically, the copper material is set as T1 copper material.

[0012] More specifically, the insulating layer is made of XLPO material.

[0013] More specifically, the inner protective layer is configured as a ceramicized silicone rubber inner protective layer.

[0014] More specifically, the protective layer is set as an aluminum tube protective layer.

[0015] More specifically, a soft conductor structure is welded to the end of the liquid-cooled wire.

[0016] A method for fabricating a liquid-cooled charging cable includes the following steps: S1, Prepare conductor by mixing copper material with metal aerogel material; S2, Prepare liquid cooling tube, and crosslink the liquid cooling tube by irradiation; S3, Prepare liquid-cooled wires by inserting the irradiated cross-linked liquid-cooled tube into a hollow conductor and extruding an insulating layer on the outside of the conductor to form liquid-cooled wires; S4, Prepare the inner sheath, prepare the liquid-cooled wires, cooling pipes and signal line groups, and extrude the inner sheath over the liquid-cooled wires, cooling pipes and signal line groups; S5, Prepare the protective layer, and form the wire by shrinking the outer protective layer of the inner protective layer; S6, bending, bending the wire to a specified angle and shape using a bending machine.

[0017] This invention addresses the shortcomings of the prior art and has the following beneficial effects: By assembling the liquid cooling pipe with the conductor, the volume of the cable is reduced, preventing breakage caused by bending, and ensuring the stability of the high-power charging system for new energy. At the same time, the use of internationally advanced extrusion and bending technology ensures the performance and structural stability of the cable. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a cross-sectional view of the liquid-cooled charging cable of the present invention; Figure 2 This is a cross-sectional view of the liquid-cooled wire of the present invention; Figure 3 This is a flowchart of the preparation method of the liquid-cooled charging cable of the present invention; In the diagram: 1. Liquid-cooled wire; 11. Liquid-cooled pipe; 12. Conductor; 13. Insulation layer; 2. Cooling pipe; 3. Signal line assembly; 4. Inner sheath; 5. Protective layer. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some, but not all, embodiments of this invention. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this invention, and should not be construed as limiting the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0020] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limiting the scope of protection of this invention. The embodiments of this invention will now be described in detail with reference to the accompanying drawings.

[0021] It should be understood that the accompanying drawings are for illustrative purposes only.

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention and therefore only show the components relevant to the present invention.

[0023] A liquid-cooled charging cable, such as Figure 1 , Figure 2 As shown, it includes a liquid-cooled wire 1, a cooling pipe 2, a signal line group 3, an inner sheath 4, and a protective layer 5. The inner sheath 4 wraps around the liquid-cooled wire 1, the cooling pipe 2, and the signal line group 3, and the protective layer 5 wraps around the inner sheath 4.

[0024] The liquid-cooled conductor 1, cooling pipe 2, and signal line group 3 are directly connected and not formed into a cable, and the inner sheath 4 is directly wrapped around the outside of the liquid-cooled conductor 1, cooling pipe 2, and signal line group 3.

[0025] The liquid-cooled wire 1 includes a conductor 12 and an insulating layer 13 wrapped around the outside of the conductor 12. The conductor 12 is configured as a hollow structure, and a liquid-cooled tube 11 is inserted inside the conductor 12.

[0026] The conductor 12 is prepared by mixing copper material and aerogel material. Further, the copper material is set as T1 copper material, and the aerogel material is set as metal aerogel. The preparation process of the metal aerogel material includes: S1, a solution of copper hydroxide metal salt is mixed with a reducing agent to form a solution of metal nanoparticles; S2, an initiator is added to the metal nanoparticle solution to form a wet gel; S3, the wet gel is dried and shaped using freeze-drying to form a metal aerogel; More specifically, the preparation process of the metal aerogel is as follows: A metal nanoparticle solution is prepared by mixing a metal salt with a reducing agent at room temperature to carry out a reduction reaction. The metal salt is chloroauric acid (HAuCl4), silver nitrate (AgNO3), etc., the reducing agent is sodium borohydride (NaBH4), sodium citrate (C6H5Na3O7), etc., and the ligand is sodium citrate (C6H5Na3O7), polyvinylpyrrolidone (PVP), etc. The concentration of the metal salt solution is controlled at 0.1-0.5 mol / L, and the concentration of the reducing agent is adjusted according to the concentration of the metal salt solution, typically 0.1-0.5 mol / L. The pH of the reaction system is controlled between 7 and 9 to ensure the smooth progress of the reaction.

[0027] To ensure the controllable synthesis and stable assembly of metal nanoparticles, and to guarantee the subsequent formation of porous aerogel structures, performance optimization, and effective composite with copper rods, the association between ligands and reducing agents can be divided into two types. One is that some ligands also function as reducing agents, such as sodium citrate. These ligands are contained in the reducing agent system and play a simultaneous role in reduction and ligand regulation when mixed with metal salts. The other is that the ligands and reducing agents are separate, such as polyvinylpyrrolidone. In this case, they need to be added together with reducing agents such as sodium borohydride to the metal salt solution for synergistic effect.

[0028] When the molar ratio (R / M) of reducing agent to metal is set to be greater than 50, sodium borohydride or sodium citrate can simultaneously function as a reducing agent, ligand, and initiator. Under these conditions, no additional ligands need to be added. The inherent properties of sodium borohydride or sodium citrate can cover the core role of the ligand, namely, the role of regulating the size of nanoparticles and adjusting the surface charge. At the same time, the subsequent gelation time can be significantly shortened from the traditional several days to 4-6 hours.

[0029] When the molar ratio (R / M) of the reducing agent to the metal is set to less than or equal to 50, sodium borohydride or sodium citrate cannot fully exert the ligand effect, and additional ligands need to be added. If the original reducing agent is sodium borohydride, sodium citrate or PVP can be added. Both can coat the surface of nanoparticles through coordination, making up for the lack of ligand function of sodium borohydride, inhibiting particle aggregation and regulating size. If the original reducing agent is sodium citrate, since sodium citrate itself has ligand properties, it is preferred to add sodium citrate as a ligand, which can simultaneously and moderately improve the reducing ability and avoid introducing other substances that may cause system interference. If other reducing agent systems are used, sodium citrate, polyvinylpyrrolidone, etc. can also be selected as ligands. Ligands can control the size of nanoparticles within the range of 1-2 nm and regulate the surface charge of nanoparticles, thereby affecting subsequent assembly behavior. Among them, the metal aerogel framework prepared by polyvinylpyrrolidone can have a size as low as 4.8 nm and a specific surface area of ​​59.8 m² / g, which can significantly improve the electrocatalytic activity of aerogels.

[0030] When the amount of reducing agent is insufficient, i.e., R / M≤50, the reduction of metal ions will be incomplete, resulting in nanoparticles with low purity, uneven size, and insufficient coordination protection on the surface, making them prone to aggregation. On the other hand, insufficient reducing agent cannot effectively play the roles of ligand and initiator, which not only fails to regulate the assembly behavior of nanoparticles but also hinders the gelation process, significantly prolonging the gelation time or preventing the formation of self-supporting wet gels. Even if gelation is barely achieved, the uneven skeleton structure will lead to the collapse of the porous structure of the aerogel after drying and a decrease in specific surface area, ultimately affecting the adsorption performance of the aerogel and its overall performance after being combined with copper rods.

[0031] Experimental data show that when the R / M ratio is below 50, the dispersibility of nanoparticles decreases significantly regardless of whether sodium borohydride or sodium citrate is used as the reducing agent. For example, in the sodium citrate-reduced chloroauric acid system, when the R / M ratio is only 4-6, the prepared gold nanoparticles have a particle size of 13.8-18.2 nm, which far exceeds the target range of 1-2 nm and is unevenly distributed, completely failing to meet the requirements for the preparation of metal aerogels. However, when the R / M ratio is increased to above 50, the nanoparticle size can be stabilized within the target range, and the dispersibility is excellent, providing a prerequisite for subsequent gelation and ensuring the performance of the aerogel.

[0032] Adding salt initiators to a metal nanoparticle solution disrupts the stable layer on the particle surface and neutralizes its surface charge through salting-out and ligand removal, thereby inducing directional aggregation and assembly of nanoparticles to form a wet gel. Suitable salt initiators include sodium chloride (NaCl), ammonium thiocyanate (NH4SCN), and potassium chloride (KCl). Different salts allow for adjustment of the cation charge density, controlling the gel framework size between 6.9 and 113.7 nm. High charge density cations (such as NH4) are particularly effective in this process. +This process can enhance the interaction with metal nanoparticles, promote isotropic assembly, and form a fine framework, such as 9 nm Au aerogel. The NaOH / NaCl mixed salt system allows for continuous adjustment of the framework width from 64 nm to 9 nm by adjusting the pH value. To further shorten the gelation time, physical disturbances such as stirring, grinding, or ultrasound can be introduced into the system to overcome diffusion limitations, enabling nanoparticles to collide and combine more rapidly. This reduces the gelation time from several hours to weeks in traditional methods to several minutes, ultimately controlling the gelation time within the range of 2-48 hours.

[0033] The wet gel is freeze-dried to form a metal aerogel. This involves first freezing the wet gel at a low temperature, then placing it in a vacuum environment to allow the solvent to sublimate, ultimately producing a porous structure with a porosity exceeding 90%. Two key parameters must be controlled during the drying process: first, the freezing rate, where rapid freezing methods, such as liquid nitrogen quenching, form fine ice crystals to prevent the collapse of the macroporous structure; and second, the drying temperature, which must be below the solvent's critical temperature. For example, when using supercritical CO2 drying, the temperature needs to be controlled at 31℃ to prevent capillary forces from damaging the pore structure. If using supercritical CO2 drying, the drying pressure must be further controlled at 10 MPa and the drying temperature at 40℃.

[0034] By simultaneously adding multiple metal salts for co-reduction during the reduction reaction stage, multi-component metal aerogels with random distribution of multiple metals can be prepared, such as Au-Pd aerogels. Using a sequential bimetallic assembly method, a core metal, such as Au clusters, and a corresponding metal nanoparticle solution are first synthesized during the reduction reaction stage. After sol-gelation to obtain a wet gel of the core metal, the metal salt corresponding to the shell metal is then reduced into the system to construct a core-shell structured metal aerogel. The shell thickness can be controlled within the range of 0.8-1.5 nm by adjusting the feeding ratio of the core metal to the shell metal. During the sequential bimetallic assembly process, introducing physical perturbations such as grinding or stirring can accelerate the heterogeneous nucleation of shell metal atoms on the surface of the core metal, improving the yield of the core-shell structure. XPS analysis verified that the Au-Pd core-shell aerogel prepared using this perturbation-assisted method exhibits Pd-rich surface characteristics.

[0035] More specifically, the conductor 12 uses T1 copper material as the base material, and then produces a copper rod through a continuous casting and rolling process. The produced copper rod is then produced into a hollow copper tube through a one-time extrusion process using a Conform continuous extrusion press. The hollow copper tube conductor is then heat-treated to obtain a conductor 12 structure with a conductivity of over 100%.

[0036] To improve the mechanical and electrical properties of the conductor 12, a conventional continuous extrusion press is modified by introducing an aerogel extrusion device. Metal aerogel is continuously added through an automated flow channel above the continuously extruded copper rod. In the continuous extrusion press, the high temperature melts the copper rod, which mixes with the metal aerogel. The mixture then passes through the forming module of the continuous extrusion press to form a hollow copper tube conductor 12. The introduction of metal aerogel improves the balance between the mechanical and electrical properties of the copper conductor, while also enhancing the thermal conductivity and resistance to liquid media of the copper tube, and reducing the weight and cost of copper.

[0037] Furthermore, the traditional continuous extruder was improved by introducing an aerogel extrusion device to achieve synchronous feeding of metal aerogel and copper rod, ensuring uniform distribution of aerogel, and a special mold was designed. In addition, a multi-segment temperature gradient control system was built to optimize the aerogel distribution and the forming quality of copper tubes.

[0038] Pretreatment: The copper rod is preheated to 200-300℃, and then the surface oxide layer is removed by sanding or chemical treatment to avoid the oxide layer affecting the bonding effect between copper and metal aerogel and the subsequent molding quality.

[0039] Heating involves feeding the copper rod into an extruder and then further heating it to an extrusion temperature of 500-600℃ to achieve its optimal plasticity.

[0040] Add aerogel. The metal aerogel is evenly added to the copper rod using an aerogel extrusion device. The amount of metal aerogel added is adjusted according to the inner diameter and wall thickness of the copper tube, and is usually set to 1-2% of the volume of the copper tube.

[0041] Extrusion molding is performed at an extrusion pressure of 100-300 MPa and an extrusion speed of 0.5-2 m / min. The pressure can be flexibly adjusted according to the diameter and thickness of the copper rod, so that the copper rod is extruded into a hollow copper tube. During the process, the metal aerogel is simultaneously and evenly distributed inside the copper tube.

[0042] After cooling and extrusion, the copper tube is rapidly cooled by water or air, with the cooling rate controlled at ≤50℃ / min, in order to fix the shape of the copper tube and prevent changes in the porous structure of the metal aerogel.

[0043] Cleaning involves using deionized water to clean the extruded copper tubes, thoroughly removing any residual impurities and oxide debris from the surface.

[0044] Annealing involves placing the cleaned copper tube in an environment of 400-500℃ for annealing for 2-3 hours. Annealing eliminates the internal stress generated during the copper tube forming process and improves the comprehensive mechanical and electrical properties of the material. After annealing, the cooling rate is maintained at ≤50℃ / min for further cooling.

[0045] Copper tubes with added metal aerogel exhibit a 20% increase in strength and a 15% increase in elongation, while also improving high-temperature insulation stability and adsorption performance. During processing such as extrusion and annealing, impurities may remain. The high specific surface area and porous structure of the metal aerogel can adsorb these impurities, preventing them from forming defects within the conductor 12, reducing its conductivity, causing localized overheating during long-term electrical heating, or even damaging the structural integrity of the conductor 12. When operating outdoors or in humid environments, moisture and trace amounts of corrosive gases in the air may enter the gaps in the conductor 12. The metal aerogel can adsorb these, preventing chemical reactions with copper to form verdigris, which would increase the conductor 12's resistance, reduce transmission efficiency, or even cause line faults. Simultaneously, by adsorbing trace impurities at the interface, it reduces interface defects, ensuring the aerogel is uniformly dispersed within the copper tube, thereby guaranteeing the stability of the conductor 12's mechanical and electrical properties.

[0046] The liquid cooling tube 11 is prepared through an irradiation crosslinking process. The Shore hardness of the irradiated crosslinked liquid cooling tube 11 is 90A-95A, giving it sufficient rigidity and necessary flexibility. It is not easily expanded or deformed under the pressure of the liquid cooling system, ensuring flow rate and heat dissipation efficiency. Simultaneously, the liquid cooling tube 11 has low thermal resistance and good heat dissipation. The irradiation crosslinking enhances its strength, allowing for a reduction in wall thickness without sacrificing pressure resistance, thereby reducing thermal resistance. The material is stable and not easily corroded or swollen by the coolant, maintaining high-efficiency heat exchange over a long period. The liquid cooling tube 11 not only serves as a channel for the cooling medium but also protects the conductor 12, preventing corrosion of the conductor 12 by the cooling medium and subsequent failure.

[0047] The insulating layer 13 is made of XLPO material. In this solution, the insulating layer 13 uses a self-developed modified XLPO material, which solves the problem that the insulating layer 13 cannot effectively bond the conductor 12 under long-term high temperature and high humidity conditions, resulting in bulging and cracking failure of the insulating layer 13. At the same time, the high water absorption rate of conventional PA12 cannot meet the requirements of insulation volume resistivity under high temperature and high humidity conditions.

[0048] Furthermore, the XLPO material comprises 10-20 parts of silane coupling agent, 10-20 parts of polypropylene, 5-10 parts of aerogel material, and the balance being EVA and EPDM. Based on EVA and EPDM as the core substrate, adding 10-20 parts of silane coupling agent, 10-20 parts of polypropylene, and 5-10 parts of aerogel material yields a modified XLPO material. The XLPO material prepared in this scheme solves the problem of insulation layer 13 resistance failure under long-term high temperature and high humidity conditions, ensuring that the insulation layer 13 maintains an insulation volume resistivity of not less than 10 after undergoing an accelerated aging test at 85℃ for 35 days. 13 Ω·m ensures that the insulation layer 13 does not bulge or crack when bent, guaranteeing its performance in subsequent bending and long-term aging.

[0049] Furthermore, the insulation layer 13 is extruded using an automated short-segment extrusion process to ensure the straightness of the liquid-cooled conductor 1 end.

[0050] The signal line is mainly equipped with a temperature control component to monitor the temperature and protect the wire.

[0051] The cooling pipe 2 is configured as a circulating cooling pipe, which is used to receive the return flow of the liquid-cooled wire 1 to form a passage. At this time, the temperature of the returning liquid is higher than the temperature of the liquid inside the liquid-cooled wire 1.

[0052] The inner sheath 4 is a ceramicized silicone rubber inner sheath, and the protective layer 5 is an aluminum tube protective layer. Furthermore, the liquid-cooled conductor 1, cooling pipe 2, and signal line group 3 are integrated. More specifically, the liquid-cooled conductor 1 is provided in two groups, with four cores directly connected and not bundled into a cable, and an outer layer of ceramicized silicone rubber inner sheath is extruded. A metal aluminum tube protective layer is then formed outside the ceramicized silicone rubber inner sheath using a shrink-tube method to facilitate bending of the wiring structure. The ceramicized silicone rubber inner sheath maintains excellent flexibility at room temperature, facilitating wire laying. When exposed to open flame or high temperature, it can quickly transform into a hard, dense, and insulating ceramic protective shell, thereby ensuring the electrical circuit integrity, mechanical structural stability, and insulation performance of the wire under extreme fire conditions.

[0053] Furthermore, by bending to achieve a fixed shape, the original product avoids problems such as bulging, cracking, and signal wire core breakage caused by long-term stress inability to be released due to product bending. Bending and shaping effectively avoids these problems, while the inner sheath 4 and protective layer 5 structure more effectively protect the wire. To increase the product's flexibility and the convenience of the charging plug, a soft conductor structure is welded to the end of the liquid-cooled wire 1. Furthermore, the two liquid-cooled wires 1 are welded with soft conductor structures as an extended flexible connection, and the signal wire group 3 and cooling pipe 2 are equipped with reserved lengths, allowing the wire ends to move freely for easy charging.

[0054] A method for manufacturing a liquid-cooled charging cable, such as Figure 3 As shown, the steps include: S1, Prepare conductor 12 by mixing copper material and aerogel material to prepare conductor, wherein the copper material is selected as T1 copper material and the aerogel material is selected as metal aerogel material. First, the copper rod is pretreated, then fed into an extruder for heating, and then metal aerogel is added into the extruder. The extruder extrudes the copper rod and metal aerogel into a hollow copper tube. The hollow copper tube is then cooled and cleaned, and the cleaned copper tube is placed in an environment of 400-500℃ for annealing. After annealing, it is cooled again to obtain the desired conductor 12. The preparation process of the metal aerogel material and the detailed preparation process of the conductor are not described here. S2, Prepare liquid cooling tube 11, and irradiate crosslinking liquid cooling tube 11; S3, prepare liquid-cooled wire 1, insert the irradiated cross-linked liquid-cooled tube 11 into the hollow conductor 12 through automated equipment. After insertion, extrude an insulating layer 13 on the outside of the conductor 12 through automated equipment. The insulating layer 13 is made of modified XLPO material. The specific composition of the modified XLPO material is not described here. S4, Prepare the inner sheath 4, and prepare the direct-drive liquid-cooled wire 1, cooling pipe 2, and signal line assembly 3. Two liquid-cooled wires 1 are provided, and the inner sheath 4 is extruded over the liquid-cooled wire 2, cooling pipe 2, and signal line assembly 3. The inner sheath 4 is a ceramicized silicone rubber inner sheath. S5, Prepare protective layer 5, and form wire by shrinking the protective layer 5 outside the inner protective layer 4 using a shrinking method. The protective layer 5 is an aluminum tube protective layer. S6, bending, bending the wire to a specified angle and shape using a bending machine, and welding a soft conductor structure to the ends of the two liquid-cooled wires 1 as an extended soft connection, equipping the signal wire group 3 and cooling pipe 2 with reserved lengths so that the ends of the wires can move freely for easy charging.

[0055] This invention addresses the shortcomings of the prior art and has the following beneficial effects: By assembling the liquid cooling pipe 11 with the conductor 12, the volume of the cable is reduced, preventing breakage due to bending and ensuring the stability of the high-power charging system for new energy vehicles. Simultaneously, internationally advanced extrusion and bending technologies are employed to guarantee the performance and structural stability of the wire. The conductor 12 is constructed as a mixture of copper rod and metal aerogel, enhancing its high-temperature insulation stability and adsorption effect. Modified XLPO material is incorporated to address the resistance failure of the insulation layer 13 under long-term high temperature and humidity conditions. The ceramicized silicone rubber inner sheath maintains excellent flexibility at room temperature and rapidly transforms into a hard, dense, and insulating ceramic protective shell upon exposure to open flame or high temperature, thus ensuring the electrical circuit integrity, mechanical structural stability, and insulation performance of the wire under extreme fire conditions.

[0056] Based on the preferred embodiments of the present invention described above, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

[0057] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0058] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0059] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A liquid-cooled charging cord, characterized by: The liquid-cooled conductor (1), the cooling pipe (2), the signal line group (3), the inner protective layer (4) and the protective layer (5), the inner protective layer (4) is wrapped outside the liquid-cooled conductor (1), the cooling pipe (2) and the signal line group (3), and the protective layer (5) is wrapped outside the inner protective layer (4); The liquid-cooled conductor (1) comprises a conductor (12) and an insulating layer (13) wrapped outside the conductor (12), the conductor (12) is made of copper material and aerogel material, and the conductor (12) is provided in a hollow structure, and a liquid cooling pipe (11) is arranged in the conductor (12).

2. The liquid-cooled charging cord of claim 1, wherein: The aerogel material is metal aerogel, and the preparation process of the metal aerogel material comprises: S1, mixing copper hydroxide metal salt solution and reducing agent to form metal nanoparticle solution; S2, adding initiator to the metal nanoparticle solution to form wet gel; S3, drying the wet gel by freeze-drying to form metal aerogel.

3. The liquid-cooled charging cord of claim 2, wherein: The reducing agent is sodium borohydride or sodium citrate.

4. The liquid-cooled charging cord of claim 2, wherein: When the molar ratio of the reducing agent to the metal is less than or equal to 50, a ligand is added to the metal nanoparticle to ensure controllable synthesis and stable assembly of the metal nanoparticle.

5. The liquid-cooled charging cord of claim 4, wherein: The ligand is sodium citrate or polyvinylpyrrolidone.

6. The liquid-cooled charging cord of claim 2, wherein: The initiator is a salt initiator.

7. The liquid-cooled charging cord of claim 1, wherein: The insulating layer (13) is an XLPO material.

8. The liquid-cooled charging cord of claim 1, wherein: The inner protective layer (4) is a ceramicized silicone rubber inner protective layer.

9. The liquid-cooled charging cord of claim 1, wherein: The protective layer (5) is an aluminum pipe protective layer.

10. A method of manufacturing a liquid-cooled charging cord, the method comprising: The method for preparing the liquid-cooled charging wire according to any one of claims 1-9 comprises the following steps: ​ S1, preparing the conductor (12), mixing copper material and metal aerogel material to prepare the conductor (12); S2, preparing the liquid cooling pipe (11), and irradiating and cross-linking the liquid cooling pipe (11); S3, preparing the liquid-cooled conductor (1), inserting the irradiated and cross-linked liquid cooling pipe (11) into the hollow conductor (12), and extruding the insulating layer (13) outside the conductor (12) to form the liquid-cooled conductor (1); S4, preparing the inner protective layer (4), preparing the liquid-cooled conductor (1), the cooling pipe (2) and the signal line group (3), and extruding the inner protective layer (4) outside the liquid-cooled conductor (1), the cooling pipe (2) and the signal line group (3); S5, preparing the protective layer (5), and shrinking the protective layer (5) outside the inner protective layer (4) to form the wire; S6, bending, bending the wire through a bending machine to a specified angle and shape.

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