Aluminum alloy cable for charging new energy vehicles

Abstract

The application relates to the field of cable manufacturing, in particular to an aluminum alloy cable for charging new energy vehicles, which comprises a power line, a grounding line and a sheath, the sheath being wrapped outside the power line and the grounding line; wherein the power line comprises an inner layer conductor, an outer layer conductor wrapped on the inner layer conductor and a first insulation layer wrapped on the outer layer conductor; the inner layer conductor is composed of 6-series aluminum alloy strands; and the outer layer conductor is composed of 6-series aluminum alloy strands and 8-series aluminum alloy strands. In the application, the 6-series aluminum alloy strands are used as the center strands to improve the overall tensile property of the power line conductor, and the 8-series aluminum alloy strands are twisted in the outer layer conductor to improve the flexibility of the overall cable under repeated bending environment, so that the power line conductor is prevented from being damaged due to frequent bending.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing, and specifically to an aluminum alloy cable for charging new energy vehicles. Background Technology

[0002] Copper is currently the most mainstream conductor material for charging cables, characterized by low resistivity, excellent toughness, and good processing performance. However, copper has a high density and high raw material cost, directly resulting in large-section fast charging cables being heavy, inconvenient to handle, and expensive overall. Large-scale application is not conducive to cost control and widespread adoption across the entire new energy vehicle industry chain. In addition, the high-current conditions of high-power fast charging exacerbate cable heating, requiring further increases in conductor cross-section, further amplifying the inherent contradiction between the weight and cost of copper conductors.

[0003] To reduce cable weight and cost, electrical aluminum alloy conductors are increasingly being used in charging cables. However, existing single-grade aluminum alloy conductors all have insurmountable technical defects: 6-series electrical aluminum alloys (typically 6101 type aluminum alloy) have a conductivity of over 60% of pure copper, which can meet basic current-carrying requirements, but they have high hardness and insufficient toughness, resulting in poor conductor flexibility. Under repeated bending conditions, stress accumulation at bending points can easily occur, leading to fatigue fracture of single filaments, strands, or even the entire conductor; 8-series electrical aluminum alloys (typically 8030 type aluminum alloy) have better flexibility than 6-series aluminum alloys, but their conductivity is slightly lower, and the tensile strength of single filaments is insufficient. They are also prone to fatigue fracture during repeated bending, making them unsuitable for the long-term high-frequency use requirements of fast-charging cables.

[0004] In view of this, how to overcome the shortcomings of the existing technology has become the subject of study and solution of this invention. Summary of the Invention

[0005] The purpose of this invention is to provide an aluminum alloy cable for charging new energy vehicles.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] An aluminum alloy cable for charging new energy vehicles includes a power line, a grounding wire, and a sheath, wherein the sheath covers the outside of the power line and the grounding wire.

[0008] The power line includes an inner conductor, an outer conductor covering the inner conductor, and a first insulating layer covering the outer conductor; the inner conductor is composed of 6-series aluminum alloy strands; and the outer conductor is composed of 6-series aluminum alloy strands and 8-series aluminum alloy strands twisted together.

[0009] The functions of the power line, grounding wire, and sheath are as described above; these three are the basic structure of the cable and will not be elaborated upon here. It is understood that the power line and grounding wire are parallel structures, as are the temperature measurement unit and other components described below.

[0010] The insulation layer (such as the first insulation layer) in this application can be a TPE insulation layer, which can meet the requirements of temperature resistance and abrasion resistance, as well as the requirements of low smoke halogen-free flame retardancy.

[0011] The power line conductor employs a layered design. The inner conductor is composed of 6-series (e.g., 6101 series) aluminum alloy strands, which have high rigidity and can withstand significant bending tension. The outer conductor is composed of multiple strands of aluminum alloy wire twisted together, including 6-series and 8-series (e.g., 8010 series, 8030 series) aluminum alloy strands. The 8-series strands are flexible, and combined with the 6-series strands, this ensures the conductor possesses both flexibility and rigidity, meeting the requirements of aluminum alloy cables for charging new energy vehicles to withstand repeated bending. The power line conductor is an aluminum alloy conductor, preferably with a cross-sectional area of ​​60 square millimeters. The 6-series aluminum alloy strands can be arranged radially in both the inner and outer conductors, as shown in the attached diagram.

[0012] In summary, the conductor of the power line is improved by using 6-series aluminum alloy strands as the center strands to enhance the overall tensile strength of the conductor, and by stranding 8-series aluminum alloy strands (with slightly lower resistance) in the outer conductor to improve the overall flexibility of the cable under repeated bending conditions, thus preventing premature failure of the power line conductor due to frequent bending.

[0013] In a further technical solution, a temperature measuring unit is provided on the inner side of the sheath. The temperature measuring unit includes at least one temperature-sensing plastic optical fiber, which is attached to the first insulating layer to achieve temperature monitoring.

[0014] There can be multiple electric power lines, each arranged around the inner filler layer described below. In this case, each electric power line is bonded to at least one temperature-sensitive plastic optical fiber, and the distribution of the temperature-sensitive plastic optical fibers can be referred to the attached figure.

[0015] Temperature-sensitive plastic optical fiber can be PC (polycarbonate) plastic optical fiber, with a temperature resistance rating of over 90℃, which can meet the requirements of actual cable use.

[0016] By utilizing the characteristic that the attenuation of temperature-sensitive plastic optical fiber increases with temperature, the temperature of the entire cable can be monitored in real time to prevent safety hazards caused by overheating. The temperature-sensitive plastic optical fiber can provide timely alarms in case of overheating, and simultaneously predict the cable's lifespan limit in advance through temperature monitoring data, further reducing the risk of fire. The alarm and location implementation logic is as follows: Based on the aforementioned fiber temperature attenuation characteristics, a sensor at the end of the fiber can accurately sense the specific location of temperature rise inside the temperature-sensitive plastic optical fiber. Combined with attenuation change data, the magnitude of the temperature rise and the location of abnormal points are determined, thereby locating the parts of the cable where the temperature has increased due to aging, bending, or other problems.

[0017] Using the example of temperature-sensitive plastic optical fiber, it should be emphasized that many structures in this application are existing and their working principles can be directly referenced. Specific parameters are not emphasized. For some structures, such as the fire-resistant unit described below, the specific construction has been adjusted, but the basic working principle has not been adjusted.

[0018] It should be added that if there is no temperature measuring unit inside the cable, the heating status of the internal core wires of the cable is unknown. Once overheating intensifies, it can easily cause overload during cable operation, leading to premature aging, overheating, or even fire.

[0019] It should be noted that most current cable temperature monitoring solutions only deploy a single or a small number of point-type temperature sensors, such as NTC thermistors, at the connector terminals. This only enables temperature detection at the cable's end points and cannot provide real-time, continuous temperature monitoring of the entire cable line. Traditional point sensors cannot effectively cover the bending sections most prone to mechanical damage and abnormal heating during cable operation, as well as "thermal runaway points" caused by sudden resistance changes throughout the entire line. Furthermore, when the heat source is not directly acting on the sensor deployment point, point monitoring solutions suffer from significant response lag, easily leading to missed detections of localized overheating risks. For aluminum alloy cables, while their conductors possess significant advantages such as lightweight, low cost, and excellent flexibility, oxidation easily occurs at conductor connections, and creep effects exist throughout the line. Both of these issues can lead to abnormally increased contact resistance or localized conductor resistance, inducing randomly distributed localized overheating hazards. These localized overheating points without fixed locations are extremely difficult to detect promptly and accurately using traditional point temperature monitoring solutions, creating serious blind spots in electrical safety management. Therefore, the cable in this application uses temperature-sensitive plastic optical fiber.

[0020] A further technical solution is that the sheath is provided with a fire-resistant unit, which includes at least one fire-resistant data bus;

[0021] The fire-resistant data bus includes an aluminum-plastic composite strip, a first tin-plated copper foil braided layer, and a sheath layer, which are sequentially arranged from the inside to the outside.

[0022] The fire-resistant data bus also includes at least one bus structure housed inside the aluminum-plastic composite strip. The bus structure includes a copper conductor, a fire-resistant mica strip, and a second insulating layer sequentially arranged from the inside to the outside.

[0023] The fire-resistant data bus is the same as the fire-resistant communication bus. This application does not change its actual function, such as ensuring stable data transmission and control command interaction between devices under normal operating conditions.

[0024] The bus structure consists of a copper conductor (or a tin-plated copper conductor) plus a fire-resistant mica tape (or a fire-resistant mica tape layer) plus a second insulation layer (which can be a foamed PP second insulation layer with a temperature resistance rating of 105℃), featuring fire resistance and high temperature resistance.

[0025] The bus structure can consist of two groups, with a characteristic impedance of 120Ω for each group. After the two bus structures are twisted together, an aluminum-plastic composite tape wrapping structure is applied to their outer sides. The aluminum base thickness of the aluminum-plastic composite tape can be ≥9μm, and the wrapping overlap rate is not less than 30%. A composite shielding structure is applied to the outer side of the aluminum-plastic composite tape wrapping structure. The inner layer of the composite shielding structure can be a braided layer made of 0.10mm tin-plated copper foil wire, with a 250D nylon core added to the center of the tin-plated copper foil wire. This structural design effectively reduces the overall weight of the cable while significantly improving its flexibility. The sheath layer is a standard feature and will not be described in detail here. Using tin-plated copper foil wire instead of traditional tin-plated copper wire, and with a nylon core, reduces the weight by 60% compared to traditional copper wire, further reducing copper resource consumption. Some features in this application can reduce cable weight and cost, such as by reducing the amount of copper used.

[0026] The cable in this application is equipped with a dedicated fire-resistant unit, and its core adopts a fire-resistant data bus design, with a fire-resistant mica tape added between the conductor and the second insulation layer. In the event of a fire, even if the second insulation layer fails at high temperatures, the fire-resistant mica tape can still ensure that the fire-resistant data bus does not short-circuit within 120 minutes (tested) in a high-temperature environment of 850°C (example), ensuring that the fire warning signal can be stably and timely transmitted to the existing warning system.

[0027] A further technical solution is that the inner side of the sheath is provided with flame-retardant non-woven fabric, which covers the outside of the power line, the grounding wire and the fire-resistant unit.

[0028] The cable in this application features an internal flame-retardant oxygen barrier layer made of flame-retardant non-woven fabric, thereby improving the overall flame-retardant effect of the cable and effectively preventing the spread of fire into the cable's interior in the event of a fire. High flame-retardant, low-halogen non-woven fabric materials can be selected to ensure the overall flame-retardant performance of the cable meets standards. It is understood that the design of the flame-retardant oxygen barrier layer can be combined with fire-resistant mica tape to further ensure the normal operation of the fire-resistant data bus in high-temperature environments.

[0029] A further technical solution is that the inner side of the sheath is provided with a second tin-plated copper foil braided layer, which covers the outside of the power line, the grounding wire and the fire-resistant unit.

[0030] A second tinned copper foil braided layer (forming the outer shielding layer of the cable) can be prepared using 0.25mm tinned copper foil wire. This second tinned copper foil braided layer can cooperate with the first tinned copper foil braided layer to further ensure the electromagnetic interference resistance of the fire-resistant data bus under normal operating conditions.

[0031] In a further technical solution, the inner side of the sheath is provided with at least one infusion tube for conveying coolant, and the infusion tube is attached to the first insulation layer to achieve cooling.

[0032] The infusion tubing can be made of silicone rubber (preferably phenyl silicone rubber with high oil resistance and a low temperature resistance of -60℃) and is used to fill the cable with coolant, serving to cool the entire cable during operation. The infusion tubing is attached to at least one power line to ensure effective heat dissipation, effectively prevent temperature rise during cable overload operation, and prevent further reduction in cable current carrying capacity.

[0033] The outer layer of the silicone tubing can be covered with 250D polyester yarn braiding, with a braiding density of not less than 80%, which can improve wear resistance and protect the infusion tubing.

[0034] The wall thickness of the infusion tubing can be determined based on the cable's rated operating hydraulic pressure, the type of coolant medium used, and the overall cable structure design. This wall thickness must simultaneously meet the system's pressure-bearing and sealing requirements as well as the medium's compatibility requirements, ensuring that the cable achieves sufficient and stable cooling under rated operating conditions. Example reference values ​​are as follows: For conventional mineral transformer oil / silicone oil media, a wall thickness of 1.5 mm is recommended; for ethylene glycol media, a wall thickness of 1.6 mm is recommended; and for 3M electronic fluorinated fluid media, a wall thickness of 1.8 mm is recommended.

[0035] Continuing with the example of an infusion tube, the location of the infusion tube in the cable can be referred to in the attached diagram, but is not limited to this layout.

[0036] A further technical solution involves filling the inner side of the sheath with a filler comprising water-blocking yarn. The water-blocking yarn is absorbent, and when coolant leaks from the infusion pipe (e.g., if the infusion pipe is damaged), the water-blocking yarn effectively prevents the coolant from corroding other structures within the cable (e.g., fire-resistant data buses).

[0037] The cable uses water-blocking yarn as a water-blocking unit. When water seeps in, the water-blocking yarn expands, which can prevent premature aging of the cable due to water entering the cable end. In addition, the water-blocking unit has a certain strength (fineness 3000D, strength greater than 150N, elongation greater than 15%), which meets the requirements of repeated bending of the cable.

[0038] In a further technical solution, the inner side of the sheath is provided with an inner packing layer and an outer packing layer arranged sequentially from the inside to the outside, and the power line, the grounding wire and the infusion tube are all arranged around the inner packing layer;

[0039] The inner filler layer is constructed as a rubber filler layer;

[0040] The outer filler layer is constructed as a water-blocking yarn filler layer.

[0041] In this application, the cable interior employs a structure with a central filler and a (polyester) water-blocking yarn filling. The central filler layer (i.e., the inner filler layer) is made of a composite rubber material (such as 75 parts nitrile rubber + 40 parts EPDM rubber), which combines wear resistance, flexibility, water resistance, and oil resistance. The other parts (i.e., the outer filler layer) use a polyester water-blocking yarn structure, which features high tensile strength, high temperature resistance, and rounded filling, and also has a certain degree of water absorption. When coolant leaks out of the infusion pipe, the polyester water-blocking yarn structure can effectively prevent the coolant from corroding other structures inside the cable.

[0042] In a further technical solution, the sheath includes an inner sheath layer, an aramid fiber braided layer, and an outer sheath layer sequentially arranged from the inside to the outside, with the inner sheath layer covering the outside of the power line and the grounding wire.

[0043] The cable features a layered sheath design with an intermediate layer constructed of aramid fiber braid (braid density can be above 80%). This intermediate layer enhances the overall torsional resistance of the cable and ensures that the inner sheath continues to function even after the outer sheath wears down, thus extending the cable's lifespan. Both the inner and outer sheath layers can be made of TPU material with a temperature resistance rating of 90℃. This material is characterized by low smoke, halogen-free properties, flame retardancy, sunlight resistance, hydrolysis resistance, and corrosion resistance, further improving the cable's lifespan.

[0044] To further illustrate, the cable features a layered sheath design with an intermediate layer constructed of aramid fiber braid. This intermediate layer, a braided aramid fiber layer, prevents further damage to the outer sheath during repeated dynamic bending, facilitating repairs and ensuring the inner sheath remains unaffected. After wrapping with protective tape or tubing, the cable can continue to be used, improving its maintainability and lifespan.

[0045] The thickness of the outer sheath is preferably 1.5 to 2 times the thickness of the inner sheath.

[0046] It should be added that if the cable sheath uses a single-layer structure, once it cracks due to external stress or wear, the cracks will spread with the fatigue process of repeated bending of the cable until the single-layer sheath is completely cracked. At this point, the single-layer sheath cannot effectively protect the internal units of the cable, severely shortening the cable's service life. Furthermore, once the single-layer sheath cracks, its large thickness makes it impossible to repair, forcing the cable and charging gun assembly (existing supporting facilities) to be scrapped prematurely.

[0047] A further technical solution involves providing a signal line on the inner side of the sheath. The signal line is a conventional feature and not an innovation of this application; its specific structure and purpose are as described in existing texts and will not be elaborated upon here.

[0048] Due to the application of the above-mentioned solution, the technical solution of this application has the following advantages and effects compared with the prior art:

[0049] In the cable of this application, the conductor of the power line adopts a layered design. The inner conductor is composed of 6-series (e.g., 6101 series) aluminum alloy strands, which have high rigidity and can withstand greater flexural tension. The outer conductor is composed of multiple strands of aluminum alloy wires twisted together, including 6-series and 8-series (e.g., 8010 series, 8030 series) aluminum alloy strands. The 8-series aluminum alloy strands are flexible, and combined with the 6-series aluminum alloy strands, the conductor as a whole ensures both flexibility and rigidity, meeting the requirements of aluminum alloy cables for charging new energy vehicles to withstand repeated bending. The conductor of the power line is an aluminum alloy conductor, and its cross-sectional area is preferably 60 square millimeters. The 6-series aluminum alloy strands can be arranged radially in both the inner and outer conductors, as shown in the attached drawings.

[0050] In summary, by using 6-series aluminum alloy strands as the center strands in the conductor of the power line to improve the overall tensile strength of the conductor, and by stranding 8-series aluminum alloy strands (with slightly lower resistance) in the outer conductor, the overall flexibility of the cable under repeated bending conditions is improved, preventing premature failure of the power line conductor due to frequent bending, thus meeting the long-term high-frequency use requirements of fast charging cables. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of the structure of the aluminum alloy cable according to an embodiment of the present invention;

[0052] Figure 2 This is a schematic diagram of the structure of the power line according to an embodiment of the present invention;

[0053] Figure 3 This is a schematic diagram of the structure of the fire-resistant data bus according to an embodiment of the present invention.

[0054] In the attached diagrams above:

[0055] 1. Electric field line; 11. Inner conductor; 12. Outer conductor; 13. First insulation layer;

[0056] 2. Grounding wire;

[0057] 3. Sheath; 31. Inner sheath layer; 32. Aramid fiber braided layer; 33. Outer sheath layer;

[0058] 4- and 6-series aluminum alloy strands; 5- and 8-series aluminum alloy strands;

[0059] 6. Temperature-sensitive plastic optical fiber;

[0060] 7. Fire-resistant data bus; 71. Aluminum-plastic composite tape; 72. First tin-plated copper foil braided layer; 73. Sheath layer; 74. Copper conductor; 75. Fire-resistant mica tape; 76. Second insulation layer;

[0061] 8. Flame-retardant non-woven fabric; 9. Second tin-plated copper foil braided layer; 10. Infusion tubing;

[0062] 100, Inner packing layer; 200, Outer packing layer; 300, Signal line. Detailed Implementation

[0063] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0064] The terms "first," "second," etc., used in this article do not specifically refer to order or sequence, nor are they intended to limit this case; they are merely used to distinguish components or operations described using the same technical terms.

[0065] The terms "connection" or "positioning" as used in this article can refer to two or more components or devices making direct physical contact with each other, or making indirect physical contact with each other, or to two or more components or devices operating or moving with each other.

[0066] The terms “include,” “including,” and “have” used in this article are all open-ended, meaning they include but are not limited to.

[0067] Unless otherwise specified, the terms used herein generally have their ordinary meaning in the context of the art, the subject matter, and the specific context. Certain terms used to describe this case will be discussed below or elsewhere in this specification to provide additional guidance to those skilled in the art in describing this case.

[0068] The terms “front,” “back,” “up,” “down,” “left,” and “right” used in this article are directional terms. In this case, they are only used to describe the positional relationship between the structures and are not intended to limit the specific direction of the protection scheme or its actual implementation.

[0069] The terminology used herein is for the purpose of describing specific embodiments only and is not intended to limit the scope of this work. Singular forms such as “a,” “this,” “this,” “the,” and “the” as used herein also include plural forms.

[0070] See Figures 1-3 An aluminum alloy cable for charging new energy vehicles includes a power line 1, a grounding wire 2, and a sheath 3, wherein the sheath 3 covers the outside of the power line 1 and the grounding wire 2.

[0071] The power line 1 includes an inner conductor 11, an outer conductor 12 covering the inner conductor 11, and a first insulation layer 13 covering the outer conductor 12; the inner conductor 11 is composed of 6-series aluminum alloy strands 4; the outer conductor 12 is composed of 6-series aluminum alloy strands 4 and 8-series aluminum alloy strands 5 twisted together.

[0072] The functions of power line 1, grounding wire 2, and sheath 3 are as described above; these three are the basic structure of the cable and will not be elaborated upon here. It is understood that power line 1 and grounding wire 2 are parallel structures, as are the temperature measurement unit and other components described below.

[0073] In this embodiment, the insulating layer (such as the first insulating layer 13) can be a TPE insulating layer, which can meet the requirements of temperature resistance and wear resistance, as well as the requirements of low smoke and halogen-free flame retardancy.

[0074] The empty space inside the sheath 3 can be filled with the following filler.

[0075] The number and layout of each structure in this embodiment can be referred to the accompanying drawings, but are not limited thereto.

[0076] The conductor of power line 1 adopts a layered design. The inner conductor 11 is composed of 6-series (e.g., 6101 series) aluminum alloy strands 4 (stranded from multiple aluminum alloy strands), which has high rigidity and can withstand greater bending tension. The outer conductor 12 is composed of multiple strands of aluminum alloy wires, including 6-series aluminum alloy strands 4 and 8-series (e.g., 8010 series, 8030 series) aluminum alloy strands 5. The 8-series aluminum alloy strands 5 are flexible, and together with the 6-series aluminum alloy strands 4, ensure that the conductor as a whole has both flexibility and rigidity, which can meet the requirements of aluminum alloy cables for charging new energy vehicles to withstand repeated bending. The conductor of power line 1 is an aluminum alloy conductor, and its cross-sectional area is preferably 60 square millimeters. The 6-series aluminum alloy strands 4 can be arranged radially in both the inner conductor 11 and the outer conductor 12, as shown in the attached diagram.

[0077] In summary, in the conductor of power line 1, the overall tensile strength of the conductor is improved by using 6-series aluminum alloy strand 4 as the center strand, and the overall flexibility of the cable under repeated bending environment is improved by stranding 8-series aluminum alloy strand 5 (with slightly lower resistance) in the outer conductor 12, thus preventing premature failure of the conductor of power line 1 due to frequent bending.

[0078] It is understandable that 6-series aluminum alloy strand 4 is preferably 6101 series aluminum alloy strand, and 8-series aluminum alloy strand 5 is preferably 8010 series aluminum alloy strand, as can be found in standard GB / T3954. In the conductor of the power line 1, the proportion of 6-series aluminum alloy can be 70-75%, and the proportion of 8-series aluminum alloy can be 25-30%. This is only an expanded explanation and does not impose specific limitations.

[0079] In one embodiment of this application, a temperature measuring unit is provided on the inner side of the sheath 3. The temperature measuring unit includes at least one temperature-sensing plastic optical fiber 6, which is attached to the first insulating layer 13 to achieve temperature monitoring.

[0080] There can be multiple power lines 1, each power line 1 is arranged around the inner filler layer 100 described below. In this case, each power line 1 is attached to at least one temperature-sensitive plastic optical fiber 6. The distribution of the temperature-sensitive plastic optical fiber 6 can be referred to the attached figure.

[0081] The temperature-sensing plastic optical fiber 6 can be PC (polycarbonate) plastic optical fiber with a temperature resistance rating of over 90℃, which can meet the requirements of actual cable use.

[0082] By utilizing the characteristic that the attenuation of the temperature-sensitive plastic optical fiber 6 increases with temperature, the temperature of the entire cable can be monitored in real time to prevent safety hazards caused by overheating. The temperature-sensitive plastic optical fiber 6 can provide timely alarms in case of overheating, and simultaneously predict the cable's lifespan limit in advance through temperature monitoring data, further reducing the risk of fire. The alarm and location implementation logic is as follows: Based on the aforementioned fiber temperature attenuation characteristics, a sensor at the end of the fiber can accurately sense the specific location of temperature rise inside the temperature-sensitive plastic optical fiber 6. Combined with attenuation change data, the magnitude of the temperature rise and the location of abnormal points are determined, thereby locating the parts of the cable where the temperature has increased due to aging, bending, or other problems.

[0083] Here, we would like to emphasize, using the temperature-sensitive plastic optical fiber 6, that many of the structures in this embodiment are existing and can be directly referred to in terms of their working principles. Specific parameters are not emphasized. For some structures, such as the fire-resistant unit described below, the specific construction has been adjusted, but the basic working principle has not been adjusted.

[0084] It should be added that if there is no temperature measuring unit inside the cable, the heating status of the internal core wires of the cable is unknown. Once overheating intensifies, it can easily cause overload during cable operation, leading to premature aging, overheating, or even fire.

[0085] It should be noted that most current cable temperature monitoring solutions only deploy a single or a small number of point-type temperature sensors, such as NTC thermistors, at the connector terminals. This only enables temperature detection at the cable's end points and cannot provide real-time, continuous temperature monitoring of the entire cable line. Traditional point sensors cannot effectively cover the bending sections most prone to mechanical damage and abnormal heating during cable operation, as well as the "thermal runaway points" caused by sudden changes in resistance throughout the entire line. Furthermore, when the heat source is not directly acting on the sensor deployment point, point monitoring solutions suffer from significant response lag, easily leading to missed detections of localized overheating risks. For aluminum alloy cables, while their conductors possess significant advantages such as lightweight, low cost, and excellent flexibility, oxidation easily occurs at conductor connections, and creep effects exist throughout the line. Both of these issues can lead to abnormally increased contact resistance or localized conductor resistance, inducing randomly distributed localized overheating hazards. These localized overheating points without fixed locations are extremely difficult to detect promptly and accurately using traditional point temperature monitoring solutions, creating serious blind spots in electrical safety management. Therefore, the cable in this embodiment uses a temperature-sensing plastic optical fiber 6.

[0086] In one embodiment of this application, the sheath 3 is provided with a fire-resistant unit, which includes at least one fire-resistant data bus 7.

[0087] The fire-resistant data bus 7 includes an aluminum-plastic composite strip 71, a first tin-plated copper foil braided layer 72, and a sheath layer 73, which are sequentially arranged from the inside to the outside.

[0088] The fire-resistant data bus 7 also includes at least one bus structure housed inside the aluminum-plastic composite strip 71. The bus structure includes a copper conductor 74, a fire-resistant mica strip 75, and a second insulating layer 76 arranged sequentially from the inside to the outside.

[0089] The fire-resistant data bus 7 is the fire-resistant communication bus. In this embodiment, its actual function has not been changed. For example, it is still used to ensure stable data transmission and control command interaction between devices under normal working conditions.

[0090] The bus structure consists of a copper conductor 74 (or a tin-plated copper conductor), a fire-resistant mica tape 75 (or a fire-resistant mica tape layer), and a second insulation layer 76 (which can be a foamed PP second insulation layer with a temperature resistance rating of 105℃), featuring fire resistance and high temperature resistance.

[0091] The bus structure can be in two groups, with a characteristic impedance of 120Ω for each group. After the two bus structures are twisted together, an aluminum-plastic composite tape wrapping structure is set on the outside. The aluminum base thickness of the aluminum-plastic composite tape 71 can be ≥9μm, and the wrapping overlap rate is not less than 80%. A composite shielding structure is set on the outside of the aluminum-plastic composite tape wrapping structure. The inner layer of the composite shielding structure can be a braided layer made of 0.10mm tin-plated copper foil wire, and the center of the tin-plated copper foil wire can be a 250D nylon core. This structural design can effectively reduce the overall weight of the cable and significantly improve its flexibility. The sheath layer 73 is a conventional setting and will not be described in detail here. Using tin-plated copper foil wire instead of traditional tin-plated copper wire, and using nylon core for the copper foil wire, the weight is reduced by 60% compared to traditional copper wire, further reducing copper resource consumption. Some settings in this embodiment can reduce cable weight and cost, such as by reducing the amount of copper used.

[0092] The cable in this embodiment is equipped with a dedicated fire-resistant unit, and the core adopts a fire-resistant data bus design. A fire-resistant mica tape 75 is added between the conductor and the second insulation layer 76. When a fire occurs, even if the second insulation layer 76 fails at high temperatures, the fire-resistant mica tape 75 can still ensure that the fire-resistant data bus 7 does not short-circuit within 120 minutes (tested) in a high-temperature environment of 850°C (example), ensuring that the fire warning signal can be stably and timely transmitted to the existing warning system.

[0093] In one embodiment of this application, the inner side of the sheath 3 is provided with flame-retardant non-woven fabric 8, which covers the outside of the power line 1, the grounding wire 2 and the fire-resistant unit.

[0094] In this embodiment, the cable is internally equipped with a flame-retardant oxygen barrier layer, which is made of flame-retardant non-woven fabric 8, thereby improving the overall flame-retardant effect of the cable and effectively preventing the spread of fire to the cable interior in the event of a fire. High flame-retardant, low-halogen non-woven fabric materials can be selected to ensure the overall flame-retardant performance of the cable meets the required standards. It is understood that the design of the flame-retardant oxygen barrier layer can work in conjunction with the fire-resistant mica tape 75 to further ensure the normal operation of the fire-resistant data bus 7 in high-temperature environments.

[0095] In one embodiment of this application, the inner side of the sheath 3 is provided with a second tin-plated copper foil braided layer 9, which covers the outside of the power line 1, the grounding wire 2 and the fire-resistant unit.

[0096] A second tinned copper foil braided layer 9 (forming the outer shielding layer of the cable) can be prepared using 0.25mm tinned copper foil wire. This second tinned copper foil braided layer 9 can cooperate with the first tinned copper foil braided layer 72 to further ensure the anti-electromagnetic interference capability of the fire-resistant data bus 7 under normal operating conditions.

[0097] In one embodiment of this application, the inner side of the sheath 3 is provided with at least one infusion pipe 10 for conveying coolant, and the infusion pipe 10 is attached to the first insulating layer 13 to achieve cooling.

[0098] The infusion tube 10 can be a silicone rubber tube (a phenyl silicone rubber material with high oil resistance and resistance to low temperatures down to -60℃ can be selected) used to fill the coolant and cool the entire cable during operation. The infusion tube 10 is attached to at least one power line 1 to ensure effective heat dissipation, effectively prevent the temperature rise of the cable during overload operation, and prevent the cable current carrying capacity from further decreasing.

[0099] The outer layer of the silicone tubing can be covered with 250D polyester yarn braiding, with a braiding density of not less than 80%, which can improve wear resistance and protect the infusion tubing.

[0100] The wall thickness of the infusion tube 10 can be determined based on the rated operating hydraulic pressure of the cable, the type of coolant medium used, and the overall design of the cable structure. This wall thickness must simultaneously meet the system's pressure-bearing and sealing requirements as well as the medium compatibility requirements, ensuring that the cable achieves sufficient and stable cooling under rated operating conditions. Example reference values ​​are as follows: For conventional mineral transformer oil / silicone oil media, a wall thickness of 1.5 mm is recommended; for ethylene glycol media, a wall thickness of 1.6 mm is recommended; for 3M electronic fluorinated fluid media, a wall thickness of 1.8 mm is recommended.

[0101] The infusion tube 10 will be used as an example here. The position of the infusion tube 10 in the cable can be referred to the attached figure, but is not limited to this layout.

[0102] In one embodiment of this application, the inner side of the sheath 3 is filled with filler, which includes water-blocking yarn. The water-blocking yarn is absorbent, and when coolant leaks out of the infusion pipe 10 (e.g., if the infusion pipe 10 is damaged), the water-blocking yarn can effectively prevent the coolant from corroding other structures inside the cable (e.g., the fire-resistant data bus 7).

[0103] The cable uses water-blocking yarn as a water-blocking unit. When water seeps in, the water-blocking yarn expands, which can prevent premature aging of the cable due to water entering the cable end. In addition, the water-blocking unit has a certain strength (fineness 3000D, strength greater than 150N, elongation greater than 15%), which meets the requirements of repeated bending of the cable.

[0104] In one embodiment of this application, the inner side of the sheath 3 is provided with an inner packing layer 100 and an outer packing layer 200 sequentially arranged from the inside to the outside, and the power line 1, the grounding wire 2 and the infusion tube 10 are all arranged around the inner packing layer 100.

[0105] The inner filler layer 100 is constructed as a rubber filler layer;

[0106] The outer filler layer 200 is constructed as a water-blocking yarn filler layer.

[0107] In this embodiment, the cable interior employs a structure with a central filler and a (polyester) water-blocking yarn filler. The central filler layer (i.e., the inner filler layer 100) is made of a composite rubber material (such as 75 parts nitrile rubber + 40 parts EPDM rubber), which combines wear resistance, flexibility, water resistance, and oil resistance. The other parts (i.e., the outer filler layer 200) use a polyester water-blocking yarn structure, which features high tensile strength, high temperature resistance, and rounded filling, and also has a certain degree of water absorption. When coolant leaks out of the infusion pipe 10, the polyester water-blocking yarn structure can effectively prevent the coolant from corroding other structures inside the cable.

[0108] In one embodiment of this application, the sheath 3 includes an inner sheath layer 31, an aramid fiber braided layer 32, and an outer sheath layer 33 sequentially arranged from the inside to the outside, with the inner sheath layer 31 covering the outside of the power line 1 and the grounding wire 2.

[0109] The sheath has a three-layer design with an intermediate layer, which is an aramid fiber braided layer 32 (braiding density can be above 80%). This intermediate layer increases the overall torsional resistance of the cable and ensures that the inner sheath 3 can continue to function after the outer sheath 3 wears, thus extending the cable's service life. Both the inner sheath layer 31 and the outer sheath layer 33 can be made of TPU material with a temperature resistance rating of 90℃. This material is characterized by low smoke and halogen-free properties, flame retardancy, sunlight resistance, hydrolysis resistance, and corrosion resistance, further enhancing the cable's service life.

[0110] To further illustrate, the sheath features a three-layer design with an intermediate layer constructed of aramid fiber braided layer 32. This intermediate layer, during repeated dynamic bending of the cable, prevents further damage to the outer sheath layer 33 if the outer sheath layer 33 is damaged, facilitating repair and ensuring the inner sheath layer 31 remains unaffected. After wrapping with protective tape or a protective sleeve 3, the cable can continue to be used, improving its maintainability and service life.

[0111] The thickness of the outer sheath layer 33 is preferably 1.5 to 2 times the thickness of the inner sheath layer 31.

[0112] It should be added that if the cable sheath 3 adopts a single-layer structure, once it cracks due to external stress or wear, the crack will spread with the fatigue process of repeated bending of the cable until the single-layer sheath 3 is completely cracked. At this time, the single-layer sheath 3 cannot effectively protect the internal units of the cable, which will seriously shorten the service life of the cable. Furthermore, once the single-layer sheath 3 cracks, it cannot be repaired due to its large thickness, and the cable and charging gun assembly (existing supporting facilities) will be forced to be scrapped prematurely.

[0113] In one embodiment of this application, a signal line 300 is provided on the inner side of the sheath 3. The signal line 300 is a conventional feature and not an innovation of this embodiment. The specific structure and purpose of the signal line 300 are as described in existing literature and will not be repeated here.

[0114] In some embodiments, the signal line 300 uses a tinned copper conductor with a cross-sectional area of ​​0.2 mm² (24 AWG), and TPE insulation with an outer diameter of 1.15 mm. It may have a braided layer, a wrapping layer, and a sheath layer (all three are conventional configurations). The braided layer can be tinned copper foil, the wrapping layer can be polyester tape, and the sheath layer can be made of TPE material with a temperature resistance rating of 90°C. The signal line 300 is mainly used for general signal transmission, and its function differs from the fire-resistant data bus 7.

[0115] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An aluminum alloy cable for charging new energy vehicles, characterized in that: It includes a power line (1), a grounding wire (2), and a sheath (3), wherein the sheath (3) covers the outside of the power line (1) and the grounding wire (2); The power line (1) includes an inner conductor (11), an outer conductor (12) covering the inner conductor (11), and a first insulation layer (13) covering the outer conductor (12); the inner conductor (11) is composed of 6-series aluminum alloy strands (4); the outer conductor (12) is composed of 6-series aluminum alloy strands (4) and 8-series aluminum alloy strands (5) twisted together.

2. The aluminum alloy cable for charging new energy vehicles according to claim 1, characterized in that: The inner side of the sheath (3) is provided with a temperature measuring unit, which includes at least one temperature-sensing plastic optical fiber (6). The temperature-sensing plastic optical fiber (6) is attached to the first insulating layer (13) to realize temperature monitoring.

3. The aluminum alloy cable for charging new energy vehicles according to claim 1, characterized in that: The sheath (3) is provided with a fire-resistant unit, which includes at least one fire-resistant data bus (7). The fire-resistant data bus (7) includes an aluminum-plastic composite strip (71), a first tin-plated copper foil braided layer (72), and a sheath layer (73) arranged sequentially from the inside to the outside. The fire-resistant data bus (7) also includes at least one bus structure housed inside the aluminum-plastic composite strip (71), the bus structure including a copper conductor (74), a fire-resistant mica strip (75) and a second insulating layer (76) arranged sequentially from the inside to the outside.

4. The aluminum alloy cable for charging new energy vehicles according to claim 3, characterized in that: The inner side of the sheath (3) is provided with flame-retardant non-woven fabric (8), which covers the outside of the power line (1), the grounding wire (2) and the fire-resistant unit.

5. The aluminum alloy cable for charging new energy vehicles according to claim 3, characterized in that: The inner side of the sheath (3) is provided with a second tin-plated copper foil braided layer (9), which covers the outside of the power line (1), the grounding wire (2) and the fire-resistant unit.

6. The aluminum alloy cable for charging new energy vehicles according to claim 1, characterized in that: The inner side of the sheath (3) is provided with at least one infusion pipe (10) for conveying coolant, and the infusion pipe (10) is attached to the first insulation layer (13) to achieve cooling.

7. The aluminum alloy cable for charging new energy vehicles according to claim 6, characterized in that: The inner side of the sheath (3) is filled with filler, which includes water-resistant yarn.

8. The aluminum alloy cable for charging new energy vehicles according to claim 7, characterized in that: The inner side of the sheath (3) is provided with an inner packing layer (100) and an outer packing layer (200) arranged sequentially from the inside to the outside. The power line (1), the grounding wire (2) and the infusion tube (10) are all arranged around the inner packing layer (100). The inner filler layer (100) is constructed as a rubber filler layer; The outer filler layer (200) is constructed as a water-blocking yarn filler layer.

9. An aluminum alloy cable for charging new energy vehicles according to any one of claims 1-8, characterized in that: The sheath (3) includes an inner sheath layer (31), an aramid fiber braided layer (32) and an outer sheath layer (33) sequentially arranged from the inside to the outside. The inner sheath layer (31) covers the outside of the power line (1) and the grounding wire (2).

10. An aluminum alloy cable for charging new energy vehicles according to any one of claims 1-8, characterized in that: The inner side of the sheath (3) is provided with a signal line (300).

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