A high-power liquid-cooled cable preparation device, process and cable for super-charging stations

Abstract

The application relates to the technical field of high-power cables, and particularly discloses a high-power liquid-cooled cable preparation device for a super charging station, a process and the cable, which comprises a raw material cylinder used for placing heated aluminum alloy raw materials; a pushing assembly which comprises a pushing piston sealingly sliding along the inner wall of the raw material cylinder, a push rod slidingly connected with the pushing piston, and a power piece used for driving the pushing piston and the push rod to move; a forming die assembly which comprises an outer die arranged on one side of the raw material cylinder and a core die arranged at the end of the push rod, and a cavity adapted to the aluminum alloy conductor is formed between the outer die and the core die; and a paint spraying assembly which comprises a movable cap arranged at the end of the core die, and the end of the core die is provided with an accommodating cavity capable of accommodating the movable cap, so that the problem of difficult paint spraying in the inner cavity of the long-distance hollow aluminum alloy conductor is effectively solved, the liquid-cooled cable with stable performance and lower cost can be provided for the construction of the super charging station, and the market competitiveness of the enterprise in the arrangement of the super charging station is improved.

Description

Technical Field

[0001] This application relates to the field of high-power cable technology, and specifically discloses a high-power liquid-cooled cable manufacturing equipment, process and cable for supercharging stations. Background Technology

[0002] With the rapid popularization of electric vehicles, the construction scale of high-power fast charging stations (supercharging stations) is constantly expanding. In order to meet the high current transmission requirements and control the temperature rise of cables, liquid-cooled charging cable technology is now widely used. Liquid-cooled cables actively dissipate heat from the cable while transmitting high current through built-in cooling pipes and circulating coolant.

[0003] Currently, the conductor core of liquid-cooled charging cables is mainly made of high-purity copper. However, with the rapid increase in the number of supercharging stations, the demand for liquid-cooled cables has increased significantly. The high price and volatile nature of copper have led to a continuous rise in cable manufacturing costs, becoming a significant factor restricting the large-scale construction of supercharging networks. To reduce material costs and increase market competitiveness, the industry has begun to consider using aluminum alloys instead of copper as the conductor core material. Aluminum alloys have significantly lower density and price than copper, which can substantially reduce the material cost and overall weight of the cable.

[0004] However, to meet the same current carrying requirements, the aluminum alloy conductor needs to have a larger cross-sectional area, making its DC resistance close to that of the original copper conductor. This leads to a significant increase in heat generation and a risk of localized overheating. Furthermore, aluminum alloy materials generally have lower bending flexibility than copper, making them more prone to fatigue damage or even breakage during repeated bending, which will affect the service life and ease of operation of the liquid-cooled cable.

[0005] Currently, cables typically use hollow aluminum alloy conductors, forming a hollow cavity within the conductor to improve heat dissipation and bending performance. To prevent electrochemical corrosion or other chemical erosion of the aluminum alloy inner wall by the coolant, a protective paint layer must be sprayed onto the surface of this hollow cavity for isolation. However, as the length of liquid-cooled charging cables increases, the process of uniformly, completely, and flawlessly spraying protective paint onto the slender, deep-hole hollow aluminum alloy conductor cavity becomes drastically more difficult. Ensuring the protective quality and consistency of the conductor's inner wall over long distances becomes a bottleneck restricting the large-scale application of this technology.

[0006] In view of this, the present invention provides a high-power liquid-cooled cable manufacturing equipment, process and cable for supercharging stations, in order to solve the above problems. Summary of the Invention

[0007] The purpose of this invention is to solve the problem of difficult coating of protective paint on the inner cavity of long-distance hollow aluminum alloy conductors, so as to break through the application bottleneck of liquid-cooled cables with aluminum alloy conductors.

[0008] To achieve the above objectives, the basic solution of the present invention provides a high-power liquid-cooled cable manufacturing device for supercharging stations, comprising:

[0009] Raw material cylinder, used to hold heated aluminum alloy raw materials;

[0010] The pushing assembly includes a pushing piston that slides and seals along the inner wall of the raw material cylinder, a push rod that is slidably connected to the pushing piston, and a power component for driving the pushing piston and the push rod to move.

[0011] The molding module includes an outer mold located on one side of the raw material cylinder and a core mold located at the end of the push rod. A cavity adapted to the aluminum alloy conductor is formed between the outer mold and the core mold. When the piston is pushed to squeeze the aluminum alloy raw material in the raw material cylinder, the aluminum alloy raw material is extruded and formed along the cavity.

[0012] A painting assembly, the painting assembly including a movable cap disposed at the end of the core mold, the end of the core mold having a receiving cavity for accommodating the movable cap;

[0013] When the core mold has not reached the position that matches the outer mold, the movable cap is sealed and fitted with the receiving cavity. When the core mold reaches the position that matches the outer mold, a paint spraying channel is formed between the movable cap and the receiving cavity, which can accommodate the spraying of protective paint.

[0014] Furthermore, the painting assembly also includes a guide rod slidably connected to the receiving cavity, one end of the guide rod being connected to the movable cap, and the guide rod being elastically connected to the push rod and driven by the same power component.

[0015] Furthermore, it also includes a limiting block. The outer wall of the push rod is provided with a retaining ring that can contact the limiting block. When the core mold reaches the position that matches the outer mold, the retaining ring contacts the limiting block and restricts the movement of the push rod.

[0016] Furthermore, a gap is formed between the guide rod and the inner wall of the receiving cavity to allow the protective paint to flow. The end of the guide rod away from the movable cap is provided with a sealing plug that is slidably and sealingly connected to the receiving cavity. One end of the sealing plug extends out of the receiving cavity and is provided with a connecting plate. A pressure spring is provided between the connecting plate and the retaining ring.

[0017] The power component drives the connecting plate to move, thereby driving the guide rod and the push rod to move.

[0018] Based on the same inventive concept, this invention also provides a manufacturing process for a high-power liquid-cooled cable for supercharging stations, including the use of the aforementioned high-power liquid-cooled cable manufacturing equipment and a high-power liquid-cooled cable with a hollow aluminum alloy conductor, the steps of which are as follows:

[0019] Step S1: Prepare aluminum alloy conductor by pushing the component to squeeze the aluminum alloy raw material in the raw material cylinder, so that the aluminum alloy raw material is extruded along the cavity to form a shape.

[0020] Step S2: Embed the aluminum alloy conductor inside the coolant pipe, and sequentially extrude an insulation layer, configure a shielding layer, and extrude a protective sleeve.

[0021] Based on the same inventive concept, the present invention also provides a high-power liquid-cooled cable for supercharging stations, wherein the cable is prepared by the above-mentioned high-power liquid-cooled cable preparation equipment or by the above-mentioned process.

[0022] Furthermore, the cable includes:

[0023] The aluminum alloy conductor has a hollow inner cavity inside, which serves as a coolant channel for the flow of coolant.

[0024] A coolant pipe is coaxially arranged with the aluminum alloy conductor and sleeved on the outside of the aluminum alloy conductor;

[0025] An insulating layer, a shielding layer, and a sheath are sequentially fitted over the outside of the coolant pipe, thus encasing the coolant pipe and the aluminum alloy conductor.

[0026] Furthermore, the outer wall of the aluminum alloy conductor and the inner wall of the coolant channel are both coated with protective paint, and the coolant in the coolant pipe and the coolant channel flows along the surface of the protective paint.

[0027] Furthermore, the inner wall of the coolant pipe is provided with several elastic contacts that can contact the outer wall of the aluminum alloy conductor.

[0028] Furthermore, the aluminum content in the aluminum alloy conductor is greater than 95%;

[0029] The coolant pipe is a thermoplastic polyurethane hose or a perfluoroalkoxy hose.

[0030] The insulating layer is cross-linked polyethylene or irradiated cross-linked polyolefin;

[0031] The shielding layer is an aluminum-plastic composite strip;

[0032] The sheath is made of polyvinyl chloride or halogen-free flame-retardant polyolefin;

[0033] The protective paint is a high-temperature resistant silicone paint.

[0034] The principle and effect of this solution are as follows:

[0035] 1. The preparation equipment and process of the present invention can conveniently process the aluminum alloy conductor required in the cable. Considering the difficulty of spraying the protective paint inside the aluminum alloy conductor as the length increases, the protective paint is sprayed at the same time as the aluminum alloy conductor is formed. The residual heat of the aluminum alloy material itself is used to make the protective paint flow and solidify quickly and evenly, forming a dense protective layer without pores or pinholes, and the anti-corrosion and sealing performance reaches the theoretical optimal value.

[0036] 2. This invention can effectively solve the problems of poor heat dissipation and bending performance of traditional liquid-cooled cables when aluminum alloy is used as the conductor, which affects the overall service life of the liquid-cooled cable. It can provide a liquid-cooled cable with stable performance and lower cost for the construction of supercharging stations, and help improve the market competitiveness of enterprises in the deployment of supercharging stations.

[0037] 3. The cable manufactured using this invention not only uses aluminum alloy conductors instead of copper conductors to reduce the overall raw material cost of the cable, but also adopts a combination of coolant channels and coolant pipes to form a highly efficient heat dissipation system with internal and external dual circulation and direct central cooling, fundamentally overcoming the heat dissipation problem inside large-section aluminum alloy conductors; at the same time, by changing the solid conductor to a hollow structure, the flexibility of the aluminum alloy conductor is significantly improved, making the cable easier to lay and retract; and by optimizing the structure, the additional complex costs caused by performance compensation are avoided, achieving the effect of cost reduction without reducing efficiency. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This paper shows a schematic diagram of the structure of a high-power liquid-cooled cable manufacturing equipment for supercharging stations according to Embodiment 1 of this application;

[0040] Figure 2 This paper shows an enlarged view of part A in the structural schematic diagram of a high-power liquid-cooled cable manufacturing equipment for supercharging stations according to Embodiment 1 of this application;

[0041] Figure 3 This paper shows a schematic diagram of the fit between the movable cap and the receiving cavity in a high-power liquid-cooled cable manufacturing device for supercharging stations according to Embodiment 1 of this application;

[0042] Figure 4 This paper shows a schematic diagram of the connection structure between the push rod and the guide rod in a high-power liquid-cooled cable manufacturing device for supercharging stations according to Embodiment 1 of this application;

[0043] Figure 5 A schematic diagram of the structure of a high-power liquid-cooled cable for a supercharging station, as proposed in Embodiment 3 of this application, is shown. Detailed Implementation

[0044] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0045] The reference numerals in the accompanying drawings include: 1. Raw material cylinder; 2. Outer mold; 3. Discharge cylinder; 4. Push rod; 5. Sliding seat sleeve; 6. Connecting frame; 7. First power shaft; 8. Fixed guide block; 9. Moving guide block; 10. Guide rod; 11. Core mold; 12. Movable cap; 13. Sealing plug; 14. Connecting disc; 15. Second power shaft; 16. Pressure spring; 17. Retaining ring; 18. Feed sleeve; 19. Through hole; 20. Aluminum alloy conductor; 21. Coolant channel; 22. Coolant pipe; 23. Insulation layer; 24. Shielding layer; 25. Sheath; 26. Elastic contact.

[0046] A device for manufacturing high-power liquid-cooled cables for supercharging stations, used to manufacture high-power liquid-cooled cables with hollow aluminum alloy conductors, such as... Figure 1 As shown, the liquid-cooled cable manufacturing equipment includes a raw material cylinder 1 for placing aluminum alloy raw materials, a pushing component for pushing out the aluminum alloy raw materials in the raw material cylinder 1, a forming module for forming a hollow inner cavity during the pushing out of the aluminum alloy raw materials, and a spraying component for spraying organosilicon high-temperature resistant paint onto the inner wall of the hollow inner cavity during the forming process.

[0047] The left end of the raw material cylinder 1 is open to facilitate the placement of aluminum alloy raw materials into the raw material cylinder 1; of course, the top of the raw material cylinder 1 can also be equipped with an openable sealed end cap to accommodate the placement of aluminum alloy raw materials.

[0048] The pushing assembly includes a pushing piston that slides and seals along the inner wall of the raw material cylinder 1, and a push rod 4 that is slidably connected to the center of the pushing piston. The pushing piston is provided with a sliding seat sleeve 5. The push rod 4 passes through the inside of the sliding seat sleeve 5 and is slidably connected to the sliding seat sleeve 5. The sliding seat sleeve 5 and the side of the pushing piston are further reinforced and fixed by a connecting bracket 6 to reduce the deformation of the pushing piston. Two cylinders are arranged on both sides of the sliding seat sleeve 5 as power components to push the sliding seat sleeve 5 and push the piston to move. The piston rod of the power component serves as the first power shaft 7 and is fixed to the connecting bracket 6 by a mounting seat.

[0049] like Figure 1 and Figure 2As shown, the molding module includes an outer mold 2 and a core mold 11. The outer mold 2 is installed at the right end of the raw material cylinder 1, and the interior of the outer mold 2 is hollow. The discharge cylinder 3 is installed at the right end of the outer mold 2. The core mold 11 is installed at the end of the push rod 4 and moves axially with the push rod 4. After the core mold 11 moves to the hollow part of the outer mold 2, a cavity that matches the cross-section of the hollow aluminum alloy conductor is formed between the outer mold 2 and the core mold 11.

[0050] To prevent material dead zones from forming inside the raw material cylinder 1, a fixed guide block 8 is configured on the left side of the outer mold 2, while a movable guide block 9 adapted to the fixed guide block 8 is configured on the right side of the pushing piston.

[0051] like Figure 1 and Figure 3 As shown, the push rod 4 has a hollow interior forming a receiving cavity. The painting assembly includes a guide rod 10 slidably connected within the receiving cavity. One end of the guide rod 10 faces the core mold 11 and is provided with a movable cap 12. The movable cap 12 is conical. Correspondingly, the receiving cavity penetrates the core mold 11 and is provided with a conical surface adapted to the movable cap 12, so as to facilitate the spraying of protective paint onto the periphery of the hollow inner cavity of the aluminum alloy conductor.

[0052] like Figure 4 As shown, the other end of the guide rod 10 is provided with a sealing plug 13 that is slidably and sealingly connected to the inner wall of the receiving cavity. The sealing plug 13 is a rigid structure. One end of the sealing plug 13 extends out of the receiving cavity and is provided with a connecting plate 14. A retaining ring 17 is provided at the end of the push rod 4. A pressure spring 16 is provided between the connecting plate 14 and the retaining ring 17 and is sleeved on the sealing plug 13. The two ends of the pressure spring 16 are respectively connected to the retaining ring 17 and the connecting plate 14. A cylinder is used as a power component to drive the movement of the sealing plug 13 and the guide rod 10. The piston rod of the power component serves as a second power shaft 15 and is connected to the connecting plate 14.

[0053] A limiting block is installed on the ground of the processing site or on the frame of the equipment. The movement of the retaining ring 17 and the push rod 4 is restricted by the contact between the limiting block and the retaining ring 17.

[0054] During the movement of the sealing plug 13 and guide rod 10 driven by the second power shaft 15, when the push rod 4 and guide rod 10 move to the right from their left positions, the second power shaft 15 drives the connecting plate 14, guide rod 10, pressure spring 16, and push rod 4 to move to the right simultaneously. The pressure spring 16 is in a state of initial compression. The force of the pressure spring 16 and the resistance of the external aluminum alloy raw material drive the movable cap 12 to seal against the receiving cavity, preventing the aluminum alloy raw material from entering the receiving cavity and solidifying, thus preventing blockage. When the push rod 4 moves to the hollow part of the outer mold 2 where the core mold 11 enters, the limiting block stops. The movement of ring 17 causes obstruction, preventing push rod 4 from moving. The second power shaft 15 only drives the sealing plug 13 and guide rod 10 to move. At this time, the pressure spring 16 is further compressed, causing relative movement between guide rod 10, movable cap 12, push rod 4, and receiving cavity, resulting in a paint spraying channel between movable cap 12 and receiving cavity. When push rod 4 and guide rod 10 move to the left from the right end position, the second power shaft 15 drives connecting plate 14, guide rod 10, and movable cap 12 to move. Movable cap 12 fits against the inner wall of the receiving cavity and drives push rod 4 to move to the left as a whole through the conical surface.

[0055] like Figure 3 and Figure 4 As shown, in this embodiment, the upper and lower sides of the guide rod 10 adopt a flat planar structure, so that a gap is formed between the guide rod 10 and the inner wall of the receiving cavity to accommodate the flow of protective paint or the installation of protective paint pipes, so as to facilitate the transport of protective spray to the movable cap 12. A feed sleeve 18 that moves synchronously with the push rod 4 is installed on the outer wall of the push rod 4, and the push rod 4 on which the feed sleeve 18 is installed has a through hole 19 that connects the feed sleeve 18 to the inside of the receiving cavity. The feed sleeve 18 is connected to an external pipe and a pump body, supplying a mixture of silicone high-temperature resistant paint and nitrogen to the receiving cavity or the protective paint pipe. This not only realizes the atomization and delivery of the paint, but also forms a local protective atmosphere on the nascent aluminum surface at the moment the paint is sprayed, thus simultaneously achieving the two functions of spraying and anti-oxidation.

[0056] The process of using the high-power liquid-cooled cable manufacturing equipment for supercharging stations in this embodiment is as follows:

[0057] First, the first power shaft 7 moves the piston out of the raw material cylinder 1 or to the left end of the raw material cylinder 1 so that aluminum alloy raw material can be fed from the left end or the top of the raw material cylinder 1; then the second power shaft 15 moves the push rod 4 to the left until the core mold 11 at the end of the push rod 4 is completely inside the push piston.

[0058] Next, aluminum alloy raw materials heated to 480-520℃ are placed into raw material cylinder 1 from the left end or the top of raw material cylinder 1.

[0059] Then, the push rod 4 is pushed to the right by the second power shaft 15, passing through the aluminum alloy material until the core mold 11 extends into the hollow part of the outer mold 2, so that a cavity is formed between the outer mold 2 and the core mold 11. Then, the conductor is pushed to the right by the second power shaft 15, so that the guide rod 10, the movable cap 12 and the push rod 4 and the receiving cavity form relative motion, and the movable cap 12 separates from the inner wall of the receiving cavity and forms a painting channel.

[0060] Finally, the first power shaft 7 moves the piston, which in turn squeezes the aluminum alloy material in the material cylinder 1, causing the aluminum alloy material to move along the cavity to the discharge cylinder 3. As the aluminum alloy material passes through the cavity, a hollow inner cavity is formed inside. At the same time, the external pipe and pump body supply a mixture of silicone high-temperature resistant paint and nitrogen to the receiving cavity or protective paint pipe through the feeding sleeve 18. The mixture of silicone high-temperature resistant paint and nitrogen is sprayed along the spraying channel onto the inner wall of the hollow inner cavity. The residual heat of the aluminum alloy causes the protective paint to flow and solidify quickly and evenly, forming a dense protective layer without pores or pinholes.

[0061] After the aluminum alloy conductor is processed and shaped, the portion of the aluminum alloy conductor located at the end is cut off for recycling and reuse. The exterior of the aluminum alloy conductor is then polished and coated with protective paint. The aluminum alloy conductor is then embedded inside the coolant pipe, and an insulation layer, a shielding layer, and a sheath are extruded in sequence to obtain a high-power liquid-cooled cable.

[0062] This equipment simultaneously completes the spraying and curing of the inner wall protective paint by utilizing residual heat while hot extruding and forming aluminum alloy conductors, achieving process integration, high efficiency, and good coating quality. Furthermore, it adopts a mixture of protective paint and nitrogen for spraying, forming a local protective atmosphere at the moment of spraying to prevent oxidation of the high-temperature aluminum inner wall, ensuring coating adhesion and conductor performance. At the same time, through the precise design of push rod 4, core mold 11, and spraying components, the timing matching and spatial accuracy of the three key processes of cavity filling, channel forming, and inner wall spraying are ensured.

[0063] Based on the same inventive concept, Embodiment 2 provides a manufacturing process for a high-power liquid-cooled cable for supercharging stations, including using the high-power liquid-cooled cable manufacturing equipment of Embodiment 1 to manufacture a high-power liquid-cooled cable with a hollow aluminum alloy conductor. The steps are as follows:

[0064] Step S1: Prepare aluminum alloy conductor. After heating the aluminum alloy raw material to 480-520℃, it is formed into an aluminum alloy conductor with a hollow inner cavity using the preparation equipment in Example 2.

[0065] Step S2: The aluminum alloy conductor is embedded inside the coolant pipe, and cross-linked polyethylene or irradiated cross-linked polyolefin is used in sequence to complete the cross-linking by extrusion at high temperature through an extruder, as an insulation layer; aluminum-plastic composite tape is wound or woven as a shielding layer; and polyvinyl chloride or halogen-free flame-retardant polyolefin is used to complete the cross-linking by extrusion at high temperature through an extruder, as a sheath.

[0066] Traditional methods are almost incapable of achieving uniform and robust coating on the inner walls of slender metal tubes exceeding several meters in length. This method fundamentally solves this problem by embedding the coating assembly within the extrusion pusher 4, which advances synchronously with the forming process, making the integrated manufacturing of ultra-long liquid-cooled cables possible.

[0067] Based on the same inventive concept, Embodiment 3 provides a high-power liquid-cooled cable for supercharging stations, such as... Figure 5 As shown: It includes an aluminum alloy conductor 20, a coolant pipe 22 arranged sequentially outwards along the aluminum alloy conductor, an insulation layer 23, a shielding layer 24, and a sheath 25. The aluminum alloy conductor 20 has a hollow inner cavity, forming a coolant channel 21 for coolant flow. The coolant pipe 22 is fitted onto the outside of the aluminum alloy conductor 20, creating a highly efficient heat dissipation system with external double circulation and central direct cooling, overcoming the heat dissipation problem inside the large-section aluminum alloy conductor 20.

[0068] The internal coolant channel 21 creates a hollow structure in the aluminum alloy conductor 20, significantly reducing its bending moment of inertia. This makes it more prone to elastic deformation without permanent damage when subjected to bending moment. Simultaneously, the hollow structure naturally reduces the weight of the conductor, further lowering the bending stress of the cable and improving operational convenience. Furthermore, based on the skin effect, at high frequencies or with high currents, the current tends to flow towards the conductor surface. The hollow aluminum alloy conductor 20 eliminates materials with low center utilization, effectively optimizing material utilization efficiency and reducing weight and cost while maintaining current carrying capacity.

[0069] Protective paint is sprayed on the outer wall of the aluminum alloy conductor 20 and the inner wall of the coolant channel 21 to improve the protection performance of the aluminum alloy conductor 20. This allows the coolant to contact the aluminum alloy conductor 20 through the protective paint, improving the contact thermal resistance between the aluminum alloy conductor 20 and the coolant, increasing the overall heat exchange efficiency, and thus improving the heat dissipation capacity. It also integrates the cooling channel with the conductor, making the cable structure more compact and reducing the thickness requirement of multiple layers of external wrapping. This effectively reduces the impact of the increased cable diameter caused by replacing the copper conductor with the aluminum alloy conductor 20.

[0070] Specifically, the aluminum alloy conductor 20 contains more than 95% aluminum, and incorporates elements such as copper to improve conductivity and strength, magnesium to increase strength and corrosion resistance, and silicon to improve casting performance. Lanthanum and cerium are also added to improve the high-temperature performance and mechanical properties of the aluminum alloy conductor 20. The coolant pipe 22 is a thermoplastic polyurethane hose or a perfluoroalkoxy tube, and its inner wall is equipped with an elastic contact 26, which contacts the outer wall of the aluminum alloy conductor 20, providing a certain deformation space for the aluminum alloy conductor 20. The insulation layer 23 is made of cross-linked polyethylene or irradiated cross-linked polyolefin. The shielding layer 24 is made of aluminum-plastic composite tape. The sheath 25 is made of polyvinyl chloride or halogen-free flame-retardant polyolefin. The protective paint is an organosilicon high-temperature resistant paint, which has multiple functions such as corrosion prevention, enhanced thermal conductivity and electrical insulation, achieving efficient heat dissipation and long-term reliability.

[0071] In summary, this invention effectively solves the problems of poor heat dissipation and bending performance of traditional liquid-cooled cables using aluminum alloy as the conductor, which affect the overall service life of the liquid-cooled cable. It can provide a liquid-cooled cable with stable performance and lower cost for the construction of supercharging stations, overcome the key technical obstacles in the application of aluminum alloy conductors in high-power liquid-cooled cables, and improve the overall performance, reliability and production efficiency of the product through high functional integration and process integration, while optimizing costs. It has strong technological advancement and market competitiveness.

[0072] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any indirect modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A device for manufacturing high-power liquid-cooled cables for supercharging stations, characterized in that, include: Raw material cylinder, used to hold heated aluminum alloy raw materials; The pushing assembly includes a pushing piston that slides and seals along the inner wall of the raw material cylinder, a push rod that is slidably connected to the pushing piston, and a power component for driving the pushing piston and the push rod to move. The molding module includes an outer mold located on one side of the raw material cylinder and a core mold located at the end of the push rod. A cavity adapted to the aluminum alloy conductor is formed between the outer mold and the core mold. When the piston is pushed to squeeze the aluminum alloy raw material in the raw material cylinder, the aluminum alloy raw material is extruded and formed along the cavity. A painting assembly, the painting assembly including a movable cap disposed at the end of the core mold, the end of the core mold having a receiving cavity for accommodating the movable cap; When the core mold has not reached the position that matches the outer mold, the movable cap is sealed and fitted with the receiving cavity. When the core mold reaches the position that matches the outer mold, a paint spraying channel is formed between the movable cap and the receiving cavity, which can accommodate the spraying of protective paint.

2. The equipment for manufacturing high-power liquid-cooled cables for supercharging stations according to claim 1, characterized in that, The painting assembly also includes a guide rod slidably connected to the receiving cavity, one end of the guide rod being connected to the movable cap, and the guide rod being elastically connected to the push rod and driven by the same power component.

3. The equipment for manufacturing high-power liquid-cooled cables for supercharging stations according to claim 2, characterized in that, It also includes a limiting block, and the outer wall of the push rod is provided with a retaining ring that can contact the limiting block. When the core mold reaches the position that matches the outer mold, the retaining ring contacts the limiting block and restricts the movement of the push rod.

4. The equipment for manufacturing high-power liquid-cooled cables for supercharging stations according to claim 3, characterized in that, A gap is formed between the guide rod and the inner wall of the receiving cavity to allow the protective paint to flow. The end of the guide rod away from the movable cap is provided with a sealing plug that is slidably and sealingly connected to the receiving cavity. One end of the sealing plug extends out of the receiving cavity and is provided with a connecting plate. A pressure spring is provided between the connecting plate and the retaining ring. The power component drives the connecting plate to move, thereby driving the guide rod and the push rod to move.

5. A manufacturing process for a high-power liquid-cooled cable for supercharging stations, characterized in that, The process includes using the high-power liquid-cooled cable manufacturing equipment described in any one of claims 1-4 to produce a high-power liquid-cooled cable with a hollow aluminum alloy conductor, comprising the following steps: Step S1: Prepare aluminum alloy conductor by pushing the component to squeeze the aluminum alloy raw material in the raw material cylinder, so that the aluminum alloy raw material is extruded along the cavity to form a shape. Step S2: Embed the aluminum alloy conductor inside the coolant pipe, and sequentially extrude an insulation layer, configure a shielding layer, and extrude a protective sleeve.

6. A high-power liquid-cooled cable for supercharging stations, characterized in that, The cable is manufactured using the high-power liquid-cooled cable manufacturing equipment as described in any one of claims 1-4, or according to the process described in claim 5.

7. A high-power liquid-cooled cable for supercharging stations according to claim 6, characterized in that, The cable includes: The aluminum alloy conductor has a hollow inner cavity to serve as a coolant channel for coolant flow. A coolant pipe is coaxially arranged with the aluminum alloy conductor and sleeved on the outside of the aluminum alloy conductor; An insulating layer, a shielding layer, and a sheath are sequentially fitted over the outside of the coolant pipe, thus encasing the coolant pipe and the aluminum alloy conductor.

8. A high-power liquid-cooled cable for supercharging stations according to claim 7, characterized in that, The outer wall of the aluminum alloy conductor and the inner wall of the coolant channel are both coated with protective paint, and the coolant in the coolant pipe and the coolant channel flows along the surface of the protective paint.

9. A high-power liquid-cooled cable for supercharging stations according to claim 8, characterized in that, The inner wall of the coolant pipe is provided with several elastic contacts that can contact the outer wall of the aluminum alloy conductor.

10. A high-power liquid-cooled cable for supercharging stations according to claim 8 or 9, characterized in that, The aluminum alloy conductor contains more than 95% aluminum. The coolant pipe is a thermoplastic polyurethane hose or a perfluoroalkoxy hose. The insulating layer is cross-linked polyethylene or irradiated cross-linked polyolefin; The shielding layer is an aluminum-plastic composite strip; The sheath is made of polyvinyl chloride or halogen-free flame-retardant polyolefin; The protective paint is a high-temperature resistant silicone paint.

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