Production process of high-power high-temperature-resistant cable and cable
By incorporating a heat dissipation mesh structure and ventilation holes within the cable, the problem of poor heat dissipation at high temperatures in high-power charging cables is solved, achieving efficient heat dissipation and structural stability, extending cable lifespan, and reducing production costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-09
- Publication Date
- 2026-05-08
AI Technical Summary
Existing high-power charging cables have poor heat dissipation under high-temperature loads, resulting in reduced service life and low production costs and efficiency.
A heat dissipation mesh structure is set between the inner core and the outer sheath of the cable, including connecting strips formed by interlocking ring tubes, and ventilation holes are opened on the outer sheath to form airflow channels for efficient heat dissipation. At the same time, the structure is stabilized by intermediate layer support and reinforcing colloid.
This technology enables efficient heat dissipation of the cable, extends its service life, reduces production costs, and improves the cable's stability and compressive strength in high-temperature environments, making it suitable for mass industrial production.
Smart Images
Figure CN122000143A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a cable structure, and more specifically, to a manufacturing process for a high-power, high-temperature resistant cable and the cable itself. Background Technology
[0002] With the development of new energy technologies, the number of electric vehicles driven by electricity has increased significantly. In order to avoid insufficient power during the operation of electric vehicles, charging piles need to be set up in cities. Charging piles are charging devices that replenish the power of electric vehicles. They function similarly to gas pumps in gas stations. They can be fixed on the ground or walls and installed in charging stations in public buildings and residential parking lots. Charging piles generally provide two charging methods: regular charging and fast charging. They can charge various models of electric vehicles according to different voltage levels.
[0003] To reduce charging time and improve the charging efficiency of electric vehicles, charging piles are gradually upgrading towards high-power, fast charging. However, when using high-power charging, the cable needs to withstand the high-temperature load brought by the high current, and also faces complex working conditions such as outdoor friction, bending installation, and fire risk. This places stringent requirements on the high-temperature resistance, flame retardancy, wear resistance, and toughness of the cable outer sheath. Currently, cooling layers are usually set between the inner cores of the cable to cool it down, but the overall heat dissipation effect is poor. In addition, additional heat dissipation structures need to be installed during processing, increasing production costs and reducing processing efficiency. Furthermore, in order to ensure the stability of the current, multiple sets of cable inner cores usually need to be bonded together, further reducing heat dissipation performance and leading to a reduction in the cable's service life. Summary of the Invention
[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a manufacturing process and cable for a high-power high-temperature resistant cable that is easy to process, has good heat dissipation effect, and can avoid excessive temperature while transmitting high-power current.
[0005] To achieve the above objectives, the present invention provides the following technical solution: a production process for a high-power high-temperature resistant cable, comprising the following steps: S1, based on the cable's usage scenario, obtaining the cable's diameter and length data, and based on the power of the current to be conducted, obtaining the diameter of the cable's inner core, and preparing the corresponding cable inner core; S2. Set a shielding layer on the outer surface of the inner core of the cable, and calculate the parameters of the outer side of the shielding layer to facilitate the setting of a buffer heat dissipation layer. S3. Cover the first inner layer and the second inner layer on the outside of the shielding layer. Before covering the second inner layer, install a heat dissipation mesh structure on the surface of the first inner layer. S4. After the heat dissipation layer is installed, the outer casing is formed using a melt extruder; Step S3 also includes a method for forming a heat dissipation mesh structure, including the following steps: S31, taking several annular tube structures, and connecting each annular tube in an "X" shaped structure to form a straight connecting strip; S32. Rubber is coated on the surface of the connecting strip. After coating, reinforcing adhesive is set at the straight pipe position of each annular pipe structure. The straight pipe with reinforcing adhesive is located at the lower end of the connecting strip formed by the connection. S33. Each of the connecting strips is arranged along the length of the cable, and is connected to the first inner layer through the straight pipe position of each annular pipe structure, and an airflow channel is formed between two adjacent connecting strips; S34. After the connecting strip is connected to the first inner layer, a reinforcing colloid is set at the straight pipe position at the other end of each annular pipe structure, and the second inner layer is wrapped on the connecting strip.
[0006] The present invention is further configured such that: after the outer shell is formed, a vent hole is provided on the surface of the outer shell, and the position of the vent hole matches the position of the channel formed by the connecting strip.
[0007] This application also discloses a cable formed by the manufacturing process of a high-power high-temperature resistant cable. The cable includes an inner core and an outer jacket sleeved on the outside of the inner core. A heat dissipation mesh structure is also provided between the inner core and the outer jacket. The heat dissipation mesh includes two inner layers, namely a first inner layer and a second inner layer that are spaced apart. One side of the first inner layer also has several protrusions. When the first inner layer is sleeved, the protrusions face the inner core of the cable. An intermediate layer is also provided between the first inner layer and the second inner layer.
[0008] Preferably, the intermediate layer is bonded between the two inner layers, and the intermediate layer includes a plurality of connecting strips evenly arranged along the circumference of the inner core of the cable and disposed along the length of the cable. The connecting strips are formed by interconnecting multiple annular tubes, so that after the connecting strips are installed, the cable can be bent in its radial direction.
[0009] Preferably, the annular tube includes two opposing semicircular rings and a connecting tube disposed between the semicircular rings, and the annular tubes are connected to each other to form an "X" shaped structure between the two inner layers.
[0010] Preferably, each of the annular tubes is further provided with a gasket, and the connecting strip is attached to the first inner layer and the second inner layer through the gasket.
[0011] Preferably, the outer casing is further provided with vent holes, which are configured to be located at both ends of the cable and at least one vent hole in the middle of the cable. The vent holes are located on the airflow channel formed by two adjacent connecting strips, and the heat dissipation mesh structure achieves heat exchange with the gas outside the cable through each vent hole.
[0012] By adopting the above technical solution, the following beneficial effects are achieved: 1. This application provides a heat dissipation mesh structure between the inner core and outer shell of the cable. The heat dissipation mesh structure can form an air circulation structure inside the cable and form an air channel between the inside and outside of the cable through the vent holes provided on the outer shell, thus avoiding the concentration of heat inside the cable. At the same time, the air circulation structure is formed by setting an intermediate layer for support inside the cable, and the intermediate layer is formed by connecting several annular tubes. While supporting the cable, it has a large number of pores for airflow, which is simple to install, has low production cost, and has a good support effect, ensuring the compressive strength of the cable in the radial direction. The chain structure formed by the interconnection of multiple annular tubes makes the overall structure have a good bending effect. Moreover, the outer shell structure of this application is integrally formed on the second inner layer, which has high production efficiency and is suitable for mass industrial production.
[0013] 2. Furthermore, this application incorporates a heat dissipation mesh structure between the inner core and the outer casing. This heat dissipation mesh structure has a first inner layer and a second inner layer for separating different layers of the cable. An intermediate layer is disposed between the first and second inner layers. The intermediate layer includes several connecting strips, and airflow channels are formed between adjacent connecting strips. Ventilation holes are provided on the outer casing at positions corresponding to the airflow channels, allowing the airflow channels to communicate with the external environment and exchange heat. Specifically, when the cable transmits current, the heat generated by the cable core heating the intermediate layer is due to contact between the first inner layer and the cable core. The air can expel hot air to the outside of the cable through the airflow channels and vents formed between adjacent connecting strips. When there are no vents in the current airflow channel, hot air can enter the other airflow channels through the gaps between the annular tubes, thus ensuring the uniformity of the cable temperature while expelling hot air. After the hot air is expelled, cold air can enter the cable through the vents, forming convection to continuously remove heat. The overall heat dissipation pad is highly efficient. Furthermore, the connecting strips form an "X" shape between the two inner layers, increasing the overall structural strength and preventing the second inner layer from being compressed, thereby reducing the airflow effect of the airflow channel.
[0014] 3. Meanwhile, the connecting strip of this application is formed by connecting annular tubes inclined in a first direction and annular tubes inclined in a second direction, ensuring the consistency of the connecting strips after installation. After the annular tubes are connected, a gasket is set on the connecting tube of the annular tube, and the connecting strip is connected to the first inner layer and the second inner layer through the gasket. After connection, the adjacent annular tubes have a rotation amount centered on the connection point, which facilitates bending during cable use. In addition, by setting a reinforcing colloid at the straight tube position of the annular tube structure, the movement of the connecting strip in the length direction and / or circumferential direction of the cable core can be prevented, avoiding the entanglement or misalignment of each connecting strip inside the cable. A stable connection interface can be formed between the first inner layer and the second inner layer. The overall processing difficulty is low, the operation is simple, and large-scale continuous production can be carried out, reducing production time and production costs.
[0015] 4. Furthermore, during the cable production process, the heat dissipation mesh structure uses several interlocking ring tubes to form an "X"-shaped connecting strip. Rubber is coated on the surface of the connecting strips, forming a rubber layer on the surface of the ring tubes, thereby improving the connection effect. Simultaneously, after the connecting strips are arranged and fixed along the cable length, a second inner layer is fitted over the connecting strips, forming a heat dissipation mesh structure that tightly fits between the cable core and outer sheath. This ensures structural strength while enhancing heat dissipation. Specifically, during installation, to ensure the positioning of the connecting strips on the first inner layer, the connecting strips can be pre-tensioned when connecting them to the first inner layer. This allows each ring tube to be connected to the first inner layer in the same fixed manner, achieving the installation positioning of the connecting strips. After installation, the straight pipe positions of the ring tube structure are connected to the first and second inner layers, increasing the connection area and improving the connection. The strength is enhanced to prevent loosening during cable bending and to create a high degree of flexibility in bending after connection. Specifically, after the ring tubes are connected, their semi-circular structures work together to give the connecting strip a bendable effect perpendicular to the cable axis, allowing the cable to bend freely in the radial direction. This facilitates installation in confined areas. Furthermore, the "X"-shaped interlocking ring tube structure forms a chain-like mechanical transmission path when the cable is stretched, preventing the cable from being stretched by external forces and protecting the inner core from excessive tension. The rubber layer coated with the heat dissipation mesh structure and the reinforcing colloid form a whole with the first and second inner layers after vulcanization, completely encasing the metal ring tube and preventing metal oxidation and corrosion. The rubber material itself has excellent high-temperature resistance and flame-retardant properties. Combined with the continuous heat dissipation of the airflow channel, the cable can work stably for a long time in high-temperature environments, significantly extending its service life and meeting the stringent requirements of high-power fast charging scenarios. Attached Figure Description
[0016] Figure 1This is a schematic diagram illustrating the manufacturing process and specific structure of a high-power high-temperature resistant cable according to the present invention. Figure 2 This is a schematic diagram illustrating the manufacturing process of a high-power high-temperature resistant cable according to the present invention, as well as the specific structure of the connecting strip in an embodiment of the cable. Figure 3 This is a cross-sectional view of a high-power high-temperature resistant cable manufacturing process and cable embodiment of the present invention. Figure 4 This is a flowchart illustrating the manufacturing process of a high-power, high-temperature resistant cable and an embodiment of the cable according to the present invention. Figure 5 This is a flowchart illustrating the manufacturing process of a high-power high-temperature resistant cable and the molding method of a cable embodiment according to the present invention. The attached figures are labeled as follows: 1. Inner core; 2. Outer shell; 3. Heat dissipation mesh structure; 31. First inner layer; 32. Second inner layer; 33. Intermediate layer; 4. Connecting strip; 41. Annular tube; 42. Gasket; 5. Vent hole. Detailed Implementation
[0017] Reference Figures 1 to 5 The manufacturing process and cable embodiments of a high-power high-temperature resistant cable of the present invention are further described below.
[0018] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.
[0019] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.
[0020] A manufacturing process for a high-power high-temperature resistant cable includes the following steps: S1. Based on the cable's usage scenario, obtain the cable's diameter and length data, and based on the power of the current to be conducted, obtain the diameter of the cable's inner core, and prepare the corresponding cable inner core. S2. Set a shielding layer on the outer surface of the inner core of the cable, and calculate the parameters of the outer side of the shielding layer to facilitate the setting of a buffer heat dissipation layer. S3. Cover the first inner layer and the second inner layer on the outside of the shielding layer. Before covering the second inner layer, install a heat dissipation mesh structure on the surface of the first inner layer. S4. After the heat dissipation layer is installed, the outer casing is formed using a melt extruder; Step S3 also includes a method for forming a heat dissipation mesh structure, including the following steps: S31, taking several annular tube structures, and connecting each annular tube in an "X" shaped structure to form a straight connecting strip; S32. Rubber is coated on the surface of the connecting strip. After coating, reinforcing adhesive is set at the straight pipe position of each annular pipe structure. The straight pipe with reinforcing adhesive is located at the lower end of the connecting strip formed by the connection. S33. Each of the connecting strips is arranged along the length of the cable, and is connected to the first inner layer through the straight pipe position of each annular pipe structure, and an airflow channel is formed between two adjacent connecting strips; S34. After the connecting strip is connected to the first inner layer, a reinforcing colloid is set at the straight pipe position at the other end of each annular pipe structure, and the second inner layer is wrapped on the connecting strip.
[0021] After the outer shell is formed, ventilation holes are provided on the surface of the outer shell, and the position of the ventilation holes matches the position of the channel formed by the connecting strip.
[0022] This application also discloses a cable formed by the manufacturing process of a high-power high-temperature resistant cable. The cable includes an inner core 1 and an outer jacket 2 sleeved on the outside of the inner core 1. A heat dissipation mesh structure 3 is also provided between the inner core 1 and the outer jacket 2. The heat dissipation mesh includes two inner layers, namely a first inner layer 31 and a second inner layer 32 that are spaced apart. One side of the first inner layer 31 also has several protrusions. When the first inner layer 31 is sleeved, the protrusions face the inner core 1 of the cable. An intermediate layer 33 is also provided between the first inner layer 31 and the second inner layer 32.
[0023] Preferably, the intermediate layer 33 is bonded between the two inner layers, and the intermediate layer 33 includes a plurality of connecting strips 4 uniformly arranged along the circumference of the inner core 1 and disposed along the length of the cable. The connecting strips 4 are formed by interconnecting multiple annular tubes 41, so that after the connecting strips 4 are installed, the cable can be bent in its radial direction.
[0024] Preferably, the annular tube 41 includes two semicircular rings arranged opposite each other and a connecting tube disposed between the semicircular rings, and the annular tubes 41 are connected to each other to form an "X" shaped structure between the two inner layers.
[0025] Preferably, each of the annular tubes 41 is further provided with a gasket 42, and the connecting strip 4 is attached to the first inner layer 31 and the second inner layer 32 through the gasket 42.
[0026] Preferably, the outer casing 2 is further provided with vent holes 5. The vent holes 5 are configured to be located at both ends of the cable and at least one vent hole 5 is located in the middle of the cable. The vent holes 5 are located on the airflow channel formed by two adjacent connecting strips 4. The heat dissipation mesh structure 3 realizes heat exchange with the gas outside the cable through each vent hole 5.
[0027] This application incorporates a heat dissipation mesh structure 3 between the inner core 1 and the outer shell of the cable. This structure creates an airflow structure within the cable and forms an air channel between the inside and outside of the cable through vent holes 5 on the outer shell 2, preventing heat concentration inside the cable. The airflow structure also incorporates a support layer 33 within the cable, formed by connecting several annular tubes 41. This support layer provides ample space for airflow, simplifying installation, reducing production costs, and providing good support while ensuring the cable's compressive strength in the radial direction. The interlocking structure formed by the interconnected annular tubes 41 provides excellent bending performance. Furthermore, the outer shell 2 is integrally formed on the second inner layer 32, resulting in high production efficiency and suitability for mass industrial production.
[0028] Furthermore, this application incorporates a heat dissipation mesh structure 3 between the inner core 1 and the outer casing 2. The heat dissipation mesh structure 3 has a first inner layer 31 and a second inner layer 32 for separating different layers of the cable. An intermediate layer 33 is disposed between the first inner layer 31 and the second inner layer 32. The intermediate layer 33 includes several connecting strips 4, and airflow channels are formed between adjacent connecting strips 4. Ventilation holes 5 are provided on the outer casing 2 at positions corresponding to the airflow channels, allowing the airflow channels to communicate with the external environment and exchange heat. Specifically, when the cable transmits current, the inner core 1 contacts the intermediate layer through the first inner layer 31. The hot air generated by heating 33 can be discharged to the outside of the cable through the airflow channel formed between adjacent connecting strips 4 and the vent 5. When there is no vent 5 on the current airflow channel, the hot air can enter the other airflow channels through the gap between each annular tube 41, thereby ensuring the uniformity of the temperature inside the cable while discharging the hot air. After the hot air is discharged, cold air can enter the cable from the vent 5, forming convection to continuously remove heat. The overall heat dissipation pad has high efficiency. In addition, the connecting strip 4 forms an "X" shaped structure between the two inner layers, which increases the overall structural strength and prevents the second inner layer 32 from being compressed, thereby reducing the airflow effect of the airflow channel.
[0029] Meanwhile, the connecting strip 4 of this application is formed by connecting annular tubes 41 inclined in a first direction and annular tubes 41 inclined in a second direction, ensuring the consistency of the connecting strip 4 after installation. After the annular tubes 41 are connected, a gasket 42 is set on the connecting tube of the annular tube 41, and the connecting strip 4 is connected to the first inner layer 31 and the second inner layer 32 through the gasket 42. After connection, the adjacent annular tubes 41 have a rotation amount centered on the connection point, which facilitates bending during cable use. In addition, by setting a reinforcing colloid at the straight tube position of the annular tube 41 structure, the movement of the connecting strip 4 in the length direction and / or circumferential direction of the inner core 1 of the cable can be prevented, avoiding the entanglement or misalignment of each connecting strip 4 inside the cable. A stable connection interface can be formed between the first inner layer 31 and the second inner layer 32. The overall processing difficulty is low, the operation is simple, and large-scale continuous production can be carried out, reducing production time and production costs.
[0030] Furthermore, during the cable production process, the heat dissipation mesh structure 3 uses several interlocking ring tubes 41 to form an "X"-shaped connecting strip 4. Rubber is coated on the surface of the connecting strip 4, forming a rubber layer on the surface of the ring tubes 41, thereby improving the connection effect. Simultaneously, after the connecting strips 4 are arranged and fixed along the cable length, a second inner layer 32 is fitted onto the connecting strips 4, forming a heat dissipation mesh structure 3 that tightly fits between the cable core 1 and the outer sheath 2, ensuring structural strength while enhancing heat dissipation. Specifically, during installation, to ensure the positioning of the connecting strips 4 on the first inner layer 31, the connecting strips 4 can be pre-tensioned when connecting them to the first inner layer 31. This allows each ring tube 41 to be connected to the first inner layer 31 in the same fixed manner, achieving the installation positioning of the connecting strips 4. After installation, the straight pipe positions of the ring tubes 41 are connected to the first inner layer 31 and the second inner layer 32, increasing the connection... The area increases the strength of the connection, preventing loosening when the cable is bent, and creating a high degree of freedom of bending after connection. Specifically, after the ring tubes 41 are connected, the semi-circular structure of the ring tubes 41 cooperates with each other, giving the connecting strip 4 an overall bendable effect in the direction perpendicular to the cable axis, allowing the cable to bend freely in the radial direction, which is convenient for installation in narrow areas. Moreover, the "X"-shaped interlocking ring tube 41 structure forms a chain-like mechanical transmission path when the cable is stretched, preventing the cable from being extended by external forces and protecting the inner core 1 from excessive tension. The rubber layer coated on the heat dissipation mesh structure 3 and the reinforcing colloid form an integral whole with the first inner layer 31 and the second inner layer 32 after vulcanization, completely wrapping the metal ring tube 41, avoiding metal oxidation and corrosion. The rubber material itself has good high temperature resistance and flame retardant properties. Combined with the continuous heat dissipation of the airflow channel, the cable can work stably for a long time in high temperature environment, significantly extending its service life and meeting the stringent requirements of high-power fast charging scenarios. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.
Claims
1. A manufacturing process for a high-power, high-temperature resistant cable, characterized in that, Includes the following steps: S1. Based on the cable's usage scenario, obtain the cable's diameter and length data, and based on the power of the current to be conducted, obtain the diameter of the cable's inner core and prepare the corresponding cable inner core. S2. Set a shielding layer on the outer surface of the inner core of the cable, and calculate the parameters of the outer side of the shielding layer to facilitate the setting of a buffer heat dissipation layer. S3. Cover the first inner layer and the second inner layer on the outside of the shielding layer. Before covering the second inner layer, install a heat dissipation mesh structure on the surface of the first inner layer. S4. After the heat dissipation layer is installed, the outer casing is formed using a melt extruder; Step S3 also includes a method for forming the heat dissipation mesh structure. The steps include: S31, taking several annular tube structures, and connecting each annular tube in an "X" shape to form a straight connecting strip; S32. Rubber is coated on the surface of the connecting strip. After coating, reinforcing adhesive is set at the straight pipe position of each annular pipe structure. The straight pipe with reinforcing adhesive is located at the lower end of the connecting strip formed by the connection. S33. Each of the connecting strips is arranged along the length of the cable, and is connected to the first inner layer through the straight pipe position of each annular pipe structure, and an airflow channel is formed between two adjacent connecting strips; S34. After the connecting strip is connected to the first inner layer, a reinforcing colloid is set at the straight pipe position at the other end of each annular pipe structure, and the second inner layer is wrapped on the connecting strip.
2. The manufacturing process of a high-power high-temperature resistant cable according to claim 1, characterized in that, After the outer shell is formed, ventilation holes are opened on the surface of the outer shell, and the position of the ventilation holes matches the position of the channel formed by the connecting strip.
3. A cable manufactured using the production process of a high-power, high-temperature resistant cable as described in claims 1-2, characterized in that, The cable includes an inner core (1) and an outer sleeve (2) sleeved on the outside of the inner core (1). A heat dissipation mesh structure (3) is also provided between the inner core (1) and the outer sleeve (2). The heat dissipation mesh includes two inner layers, namely a first inner layer (31) and a second inner layer (32) spaced apart. The first inner layer (31) also has several protrusions on one side. When the first inner layer (31) is sleeved, the protrusions face the inner core (1) of the cable. An intermediate layer (33) is also provided between the first inner layer (31) and the second inner layer (32).
4. The cable manufactured using the production process of a high-power high-temperature resistant cable according to claim 3, characterized in that, The intermediate layer (33) is combined between the two inner layers, and the intermediate layer (33) includes a plurality of connecting strips (4) evenly arranged along the circumference of the inner core (1) of the cable and arranged along the length of the cable. The connecting strips (4) are formed by connecting each other through a plurality of annular tubes (41), so that after the connecting strips (4) are installed, the cable can be bent in its radial direction.
5. The cable manufactured using the production process of a high-power, high-temperature resistant cable according to claim 4, characterized in that, The annular tube (41) includes two semicircular rings arranged opposite each other and a connecting tube arranged between the semicircular rings, and the annular tubes (41) are connected to each other to form an "X" shaped structure between the two inner layers.
6. The cable manufactured using the production process of a high-power, high-temperature resistant cable according to claim 5, characterized in that... Each of the annular tubes (41) is provided with a gasket (42) on its connecting tube, and the connecting strip (4) is attached to the first inner layer (31) and the second inner layer (32) through the gasket (42).
7. The cable manufactured using the production process of a high-power high-temperature resistant cable according to claim 6, characterized in that, The outer casing (2) is also provided with ventilation holes (5). The ventilation holes (5) are configured to be located at both ends of the cable and at least one ventilation hole (5) is located in the middle of the cable. The ventilation holes (5) are located on the airflow channel formed by two adjacent connecting strips (4). The heat dissipation mesh structure (3) achieves heat exchange with the gas outside the cable through each ventilation hole (5).