A liquid-cooled high-current fast charging cable and its manufacturing method

Abstract

This invention relates to the field of charging cable technology, and in particular to a liquid-cooled high-current fast-charging pile cable and its manufacturing method, comprising a main core, a control core unit, a ground core, a cooling channel, an inner sheath, a total shielding layer, and an outer sheath; the main core includes a braided conductor, a semi-conductive nylon tape, main core insulation, and a central PTFE cooling tube; the control core unit includes a control core conductor, control core insulation, control core wrapping tape, and a central PTFE cooling tube; the cooling channel further includes a peripheral PTFE cooling tube. The main core of this invention, comprising a braided conductor, a semi-conductive nylon tape, main core insulation, and a central PTFE cooling tube, improves conductivity, heat dissipation, tensile strength, and fatigue resistance through a composite structure.

Description

Technical Field

[0001] This invention relates to the field of charging cable technology, and in particular to a liquid-cooled high-current fast charging pile cable and its manufacturing method. Background Technology

[0002] In recent years, the global new energy vehicle industry has entered a period of rapid upgrades to high-voltage platforms and high-power supercharging. With the mass production of models using 800V and above high-voltage platforms, users' demand for rapid energy replenishment—"ten minutes of charging for hundreds of kilometers of range"—is becoming increasingly urgent. High-power DC fast charging has become the core development direction of the industry and a key breakthrough in solving charging anxiety and promoting the popularization of the industry. According to the charging power calculation formula, with the support of high-voltage platforms, charging power has jumped from the conventional 120-250kW to 480kW, 600kW, and even megawatt levels. The corresponding charging current has increased from 200-300A to 500A and over 600A. High-current, high-density power transmission has become the core technical requirement of charging systems.

[0003] Meanwhile, the upgrading of domestic new energy vehicle charging infrastructure is accelerating, the construction of supercharging stations is progressing on a large scale, and relevant industry standards are constantly being improved, placing higher demands on the current carrying capacity, heat dissipation efficiency, lightweight design, safety, and durability of charging cables. To address the industry pain points of traditional cables—"heavy loads with high current and prone to overheating with high power"—and to overcome the bottlenecks in thermal management technology for high-power charging, while balancing efficient energy replenishment, ease of operation, and operational safety, liquid-cooled high-current fast-charging cables, deeply integrated with liquid cooling technology, have emerged as a core component suitable for high-power supercharging systems.

[0004] Traditional charging cables suffer from insufficient current carrying capacity, low heat dissipation efficiency, heavy weight, poor flexibility, and excessive temperature rise, making them unable to meet the demands of high-power fast charging. Liquid cooling technology can significantly improve current carrying capacity and reduce cable weight, but existing liquid-cooled cables have drawbacks such as unreasonable cooling channel layout, uneven heat dissipation, poor structural stability, weak electromagnetic shielding, and insufficient aging resistance, which restrict the safe and stable operation of supercharging systems. Summary of the Invention

[0005] The technical problem to be solved by the present invention is that existing liquid-cooled cables have problems such as unreasonable cooling channel layout, uneven heat dissipation, poor structural stability, weak electromagnetic shielding effect, and insufficient aging resistance.

[0006] The technical solution adopted by this invention to solve its technical problem is: a liquid-cooled high-current fast charging pile cable, comprising a main core, a control core unit, a ground core, a cooling channel, an inner sheath, a total shielding layer, and an outer sheath; the main core includes a main core braided conductor, a semi-conductive nylon tape, main core insulation, and a main core center PTFE cooling tube; the control core unit includes a control core conductor, control core insulation, control core wrapping tape, and a control core center PTFE cooling tube; the cooling channel further includes a gap PTFE cooling tube.

[0007] The main core braided conductor is centered on the PTFE cooling tube in the center of the main core and is formed by braiding multiple layers of bare copper wires, with one aramid filament inside each braided copper wire.

[0008] The semi-conductive nylon tape is wrapped around the outside of the braided conductor of the main core, and the insulation of the main core is extruded around the outside of the semi-conductive nylon tape. The material is heat-resistant to 150℃, low smoke, halogen-free, radiation-crosslinked polyolefin.

[0009] The control core unit includes six control cores and a central PTFE cooling tube for the control cores. The six control cores are evenly distributed around the cooling tube and are wrapped around the control cores with a tape.

[0010] The two main conductors, one control conductor, and one ground conductor are arranged in a triangle, with two PTFE cooling pipes installed in the gaps.

[0011] The inner sheath is made of low-smoke halogen-free flame-retardant polyurethane elastomer through extrusion full filling, filling all gaps between the wire cores.

[0012] The overall shielding layer is composed of longitudinally wrapped aluminum-plastic composite tape and bare copper lead wires, with the lead wires in close contact with the shielding layer.

[0013] The cooling channel is an independent sealed structure, including a PTFE cooling pipe at the center of the main core, a PTFE cooling pipe at the center of the control core, and a PTFE cooling pipe at the edge gap, forming a multi-loop circulating cooling system.

[0014] Both the ground wire core and the control wire core conductor are Category 5 soft bare copper stranded wires, and the insulation layer is a heat-resistant, low-smoke, halogen-free irradiated cross-linked polyolefin with a temperature resistance of 150℃.

[0015] A method for manufacturing a liquid-cooled high-current fast-charging pile cable includes the following steps: preparing a main core braided conductor, a control core conductor, and a ground core; wrapping a semi-conductive nylon tape around the main core, control core, and ground core insulation; cable-forming the control core and the central PTFE cooling tube of the control core into a cable and wrapping it; forming a cable by triangularly connecting the main core, control core unit, ground core, and edge PTFE cooling tube; extruding an inner sheath to fully fill the gaps; longitudinally wrapping an aluminum-plastic composite tape and placing a drain wire to form a total shielding layer; extruding an outer sheath; and testing the sealing performance and electrical performance.

[0016] The beneficial effects of this invention are: (1) The main core of the present invention includes a braided conductor, a semi-conductive nylon tape, a main core insulation, and a PTFE cooling tube in the center of the main core. The composite structure improves conductivity, heat dissipation, tensile strength, and fatigue resistance, increases current carrying capacity by more than 50%, and reduces weight by more than 30%. (2) Multi-loop independent cooling channels are used to achieve heat dissipation throughout the conductor, and the temperature rise is controlled within a safe range, which is suitable for high currents of 600A and above; (3) The structure is arranged in a triangle with two main cores, one control core unit and one ground core, and two PTFE cooling pipes are installed in the gaps to improve structural stability, reduce bending radius and withstand repeated bending. (4) The total shielding layer is composed of aluminum-plastic composite tape wrapped longitudinally and bare copper lead wires, which improves electromagnetic compatibility performance and ensures stable signal transmission; (5) High heat resistance, low smoke halogen-free, flame retardant and weather resistant materials extend service life and reduce operation and maintenance costs. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0018] Figure 1 This is a schematic diagram of the structure of the present invention.

[0019] 1. Main conductor braided conductor; 2. Main conductor insulation; 3. Semi-conductive nylon tape; 4. Main conductor center PTFE cooling tube; 5. Control conductor; 6. Control conductor insulation; 7. Control conductor wrapping tape; 8. Control conductor center PTFE cooling tube; 9. Ground conductor; 10. Ground conductor insulation; 11. Inner sheath; 12. Overall shielding layer; 13. Outer sheath; 14. Edge PTFE cooling tube. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] Figure 1The liquid-cooled high-current fast charging cable of the present invention shown has the following overall cross-section from the inside out: control core unit, main core, ground core, edge PTFE cooling pipe, inner sheath, total shielding layer, and outer sheath.

[0023] The control core unit is located in the central area of ​​the cable, and a central PTFE cooling tube 8 is installed inside. Six control cores are evenly distributed around the central PTFE cooling tube 8. Each control core consists of a control core conductor 5 and a control core insulation 6 from the inside out. The control core conductor 5 is made of Category 5 soft bare copper stranded wire, and the control core insulation 6 is made of heat-resistant, low-smoke, halogen-free irradiated cross-linked polyolefin with a temperature resistance of 150℃. The six control cores are wrapped with control core wrapping tape 7 to form a structurally stable control core unit.

[0024] There are two main wire cores, symmetrically distributed on both sides of the control wire core unit. Each main wire core consists of, from the inside out, a PTFE cooling tube 4 at the center of the main wire core, a braided conductor 1, a semi-conductive nylon tape 3, and insulation 2. The braided conductor 1 is formed by braiding multiple layers of bare copper wire around the PTFE cooling tube 4 at the center of the main wire core. Each braided copper wire contains an aramid filament. The semi-conductive nylon tape 3 is tightly wrapped around the outside of the braided conductor 1. The insulation 2 is extruded around the outside of the semi-conductive nylon tape 3. The material is heat-resistant to 150℃, low smoke, halogen-free irradiated cross-linked polyolefin.

[0025] The ground wire core is located in the triangular gap formed by the two main wire cores and the control wire core unit. The ground wire cores are ground wire core 9 and ground wire core insulation 10 from the inside to the outside. Ground wire core 9 is made of Category 5 soft bare copper stranded wire, and ground wire core insulation 10 is made of heat-resistant 150℃ low smoke halogen-free irradiated cross-linked polyolefin.

[0026] There are two PTFE cooling pipes 14, which are respectively set in the remaining gap positions between the two main cores, the control core unit, and the ground core. Together with the PTFE cooling pipe 4 in the center of the main core and the PTFE cooling pipe 8 in the center of the control core, they form a three-way independent sealed multi-loop circulating cooling system.

[0027] The inner sheath 11 is made of low-smoke halogen-free flame-retardant polyurethane elastomer by extrusion molding, which completely fills all the gaps between the wire core and the cooling pipe, and covers the internal structure as a whole to prevent the wire core and the cooling pipe from shifting.

[0028] The total shielding layer 12 is wrapped around the outer side of the inner sheath 11. It is composed of an aluminum-plastic composite strip and a bare copper lead wire. The lead wire is in close contact with the aluminum-plastic composite strip to achieve electromagnetic shielding, waterproofing, and rapid discharge of fault current.

[0029] The outer sheath 13 is extruded on the outside of the total shielding layer 12 and uses low-smoke halogen-free flame-retardant polyurethane elastomer to provide the cable with wear-resistant, weather-resistant, hydrolysis-resistant and flame-retardant external protection.

[0030] The manufacturing method of the liquid-cooled high-current fast charging pile cable of the present invention includes the following specific steps: Conductor preparation: The main core braided conductor 1 is made by braiding multiple layers of bare copper wires with the PTFE cooling tube 4 at the center of the main core as the core body and each braided copper wire containing an aramid filament; the control core conductor 5 and the ground core 9 are prepared by using Class 5 bare copper stranded wires respectively. Insulation extrusion: wrap semi-conductive nylon tape 3 around the outside of the main core braided conductor 1, and then extrude the main core insulation 2; extrude the control core insulation 6 around the outside of the control core conductor 5, and extrude the ground core insulation 10 around the outside of the ground core 9. Cabling of control core unit: Six extruded insulation control cores are evenly wrapped around the PTFE cooling tube 8 in the center of the control core, and the control core wrapping tape 7 is wrapped around the entire control core to form a control core unit; Cable assembly: Arrange two main conductors, a set of control conductor units, and one ground conductor in a triangular structure, and place two edge PTFE cooling pipes 14 at the edge gaps to complete the cable assembly. Inner sheath extrusion: The inner sheath 11 is extruded using low-smoke halogen-free flame-retardant polyurethane elastomer to ensure that the gap between the wire core and the cooling tube is completely filled. Overall shielding formation: Aluminum-plastic composite strip is longitudinally wrapped around the outer side of the inner sheath 11, and bare copper lead wires are placed simultaneously and made to be in close contact with the aluminum-plastic composite strip to form the overall shielding layer 12. Outer sheath extrusion: A low-smoke halogen-free flame-retardant polyurethane elastic outer sheath 13 is extruded on the outside of the total shielding layer 12; Performance testing: The cable undergoes cooling channel sealing performance testing, electrical performance testing, and mechanical performance testing. Once the test is passed, the finished cable is produced.

[0031] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, 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.

Claims

1. A liquid-cooled high-current fast charging pile cable, characterized in that, include: The main conductor, control conductor unit, ground conductor (9), cooling channel, inner sheath (11), overall shielding layer (12), and outer sheath (13) are included. The main conductor includes a main conductor braided conductor (1), a semi-conductive nylon tape (3), main conductor insulation (2), and a main conductor center PTFE cooling tube (4). The control conductor unit includes a control conductor conductor (5), control conductor insulation (6), control conductor wrapping tape (7), and a control conductor center PTFE cooling tube (8). The cooling channel also includes a side gap PTFE cooling tube (14).

2. The cable according to claim 1, characterized in that, The main core braided conductor (1) is centered on the PTFE cooling tube (4) in the center of the main core and is formed by multi-layer bare copper wire braiding, with one aramid filament inside each braided copper wire.

3. The cable according to claim 1, characterized in that, The semi-conductive nylon tape (3) is wrapped around the outside of the main core braided conductor (1), and the main core insulation (2) is extruded around the outside of the semi-conductive nylon tape (3). The material is heat-resistant 150℃ low smoke halogen-free irradiated cross-linked polyolefin.

4. The cable according to claim 1, characterized in that, The control core unit includes six control cores and a central PTFE cooling tube (8) for the control cores. The six control cores are evenly distributed around the cooling tube and are wrapped around the control cores with a wrapping tape (7).

5. The cable according to claim 1, characterized in that, Two main wire cores, one control wire core unit, and one ground wire core (9) are arranged in a triangle, with two edge PTFE cooling pipes (14) installed in the gap.

6. The cable according to claim 1, characterized in that, The inner sheath (11) is made of low-smoke halogen-free flame-retardant polyurethane elastomer by extrusion full filling, filling all gaps between the wire cores.

7. The cable according to claim 1, characterized in that, The total shielding layer (12) is composed of an aluminum-plastic composite strip longitudinally wrapped with bare copper lead wires, and the lead wires are in close contact with the shielding layer.

8. The cable according to claim 1, characterized in that, The cooling channel is an independent sealed structure, including a main core center PTFE cooling pipe (4), a control core center PTFE cooling pipe (8), and a side gap PTFE cooling pipe (14), forming a multi-loop circulating cooling system.

9. The cable according to claim 1, characterized in that, The ground conductor (9) and the control conductor (5) are both Class 5 soft bare copper stranded wires, and the insulation layer is a heat-resistant, low-smoke, halogen-free irradiated cross-linked polyolefin with a temperature resistance of 150℃.

10. A method for manufacturing a liquid-cooled high-current fast-charging pile cable according to any one of claims 1-9, characterized in that, The steps include: preparing the main core braided conductor (1), control core conductor (5), and ground core (9); wrapping with semi-conductive nylon tape (3); extruding the main core insulation (2), control core insulation (6), and ground core insulation (10); cabling the control core and the central PTFE cooling tube (8) of the control core and wrapping it; forming a cable by triangularly forming the main core, control core unit, ground core (9), and edge PTFE cooling tube (14); extruding the inner sheath (11) to fully fill the gap; longitudinally wrapping with aluminum-plastic composite tape and placing the drain wire to form the total shielding layer (12); extruding the outer sheath (13); and testing the sealing performance and electrical performance.

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