A high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles and a production process thereof

Abstract

The application discloses a high-flexibility liquid-cooling high-power monitoring cable for new energy vehicles and a production process. The cable comprises, from inside to outside, a liquid leakage monitoring line, a cable core, a wrapping layer and a sheath. The cable core comprises a ground wire core, a control wire core group, a power wire core and a cooling pipe. The power wire core comprises a power conductor, a cooling flow channel and a power core insulation. The cooling flow channel is provided with cooling liquid, and the power core insulation adopts a threaded structure. The cable is additionally provided with the liquid leakage monitoring line in the center, so that the leakage of the cooling liquid can be timely fed back, and the risk of short circuit and heating caused by the leakage of the cooling liquid is effectively solved. The threaded insulation of the cable adopts the threaded structure, so that the softness of the cable is improved, and the bending radius of the cable is reduced by more than 30%.

Description

Technical Field

[0001] This invention relates to the field of monitoring cable technology, and in particular to a highly flexible liquid-cooled high-power monitoring cable for new energy vehicles and its manufacturing process. Background Technology

[0002] In recent years, the rapid development of new energy vehicles has led to slow charging speeds, which severely impact user experience and reduce the efficiency of charging stations. Traditional DC charging cables typically carry a current of no more than 250A and take over 2 hours to charge. While increasing conductor cross-section can improve charging speed, it increases cable weight and inconvenience. Liquid cooling can significantly increase current carrying capacity, reduce cable diameter and weight, and improve user experience. However, liquid-cooled high-power charging cables are prone to bending, dragging, and coiling during use, which can lead to issues such as cooling pipe detachment from connectors, cooling pipe rupture, and liquid leakage. Liquid leakage can cause short circuits and overheating, affecting the charging safety of new energy vehicles. Furthermore, bending the liquid cooling pipe can cause wrinkles, resulting in reduced flow and pipe breakage. Therefore, it is necessary to design a new type of liquid-cooled high-power charging cable that is easy to bend and has monitoring capabilities, along with its manufacturing process. Summary of the Invention

[0003] The technical problem to be solved by this invention is that existing liquid-cooled charging cables lack accurate leakage monitoring, are prone to leakage and short circuits, have insufficient cable flexibility, are easily wrinkled when bent, and have reduced cooling flow.

[0004] The technical solution adopted by this invention to solve its technical problem is: a high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles, comprising, from the inside out, a leakage monitoring line, a cable core, a wrapping layer, and a sheath; the cable core includes: a ground core, a control core group, a power core, and a return tube; The leakage monitoring line includes: a monitoring core, a monitoring conductor, monitoring insulation, a braided shield, and a support component; The ground wire core includes: a ground wire conductor and ground wire insulation; The control conductor assembly includes: a control conductor and control insulation; The power core includes: a power conductor, a cooling channel, and threaded insulation.

[0005] The leakage monitoring line is set in the gap between the ground wire core and the power wire core. There are 2 monitoring wire cores and 2 support members. The monitoring wire cores are located in the gap between the 2 support members and do not contact each other. The monitoring wire cores and support members are arranged in a spiral.

[0006] The monitoring insulation is made of conductive polyethylene, and a braided shield is provided on the outside of the monitoring insulation. The braided shield is made of PP fiber or aramid fiber.

[0007] The control core group consists of at least 4 control cores, and the control cores can be divided into multiple unit control core pairs and disposed in the gap between the ground core, power core and return pipe.

[0008] The cooling channel and return pipe are circulated with cooling liquid, which can be water, a mixture of water and ethylene glycol, a mixture of water and propylene glycol, etc.

[0009] The thread insulation is in the shape of a continuous thread, with a spacing of 1~5mm between the inner side of the thread trough and the outer side of the thread crest. The core conductor and threaded insulation form a cooling channel.

[0010] The threaded insulation and return pipe are made of fluoroplastics, which meet the requirements of retaining ≥70% of tensile strength and elongation at break after aging in hot air at 260℃ for 7 days, retaining ≥70% of tensile strength and elongation at break after immersion in cooling liquid at 150℃ for 7 days, and having a swelling rate ≤10%.

[0011] The wrapping layer uses lubricated wrapping paper with an overlap rate of 10% to 30%.

[0012] The sheath is made of TPU material.

[0013] The technical solution for achieving the second objective of this invention is a manufacturing process for a highly flexible liquid-cooled high-power monitoring cable for new energy vehicles, comprising the following steps: Step 1: Determine the cable structure; Step 2: Fabricate a leak detection line; Step 3: Fabricate the ground conductor, control conductor, and power conductor; Step 4: Fabricate threaded insulation and return tubing; Step 5: Extrude ground insulation from the ground conductor and extrude control insulation from the control conductor; Step Six: Irradiate crosslinking of the ground wire insulation and control insulation; Step 7: Insert the thread insulation into the thread insulation; Step 8: Control cable cores are divided into groups and cabled to form control wire pairs; Step 9: Assemble the leakage monitoring line, ground wire core, control wire core group, power wire core and return pipe into a cable, and wrap it with a sheath; Step 10: Extrude the sheath around the outer layer of the cladding.

[0014] In step two, the method for making the leakage monitoring line is as follows: first, make the monitoring conductor, then extrude the monitoring insulation from the monitoring conductor, then make the braided shield on the outside of the monitoring insulation to make the monitoring wire core, and arrange the two support members and the two monitoring wire cores at intervals to form a cable, with the cable pitch being 10 to 30 times the outer diameter of the total cable.

[0015] In step seven, a 2mm diameter steel wire rope is first threaded into the threaded insulation using a threading machine, then the power conductor is connected to the steel wire rope, and finally pulled into the threaded insulation.

[0016] The eleventh step involves extruding the sheath, which is produced by extrusion at a temperature of 175°C.

[0017] The beneficial effects of this invention are: (1) By adopting a dual monitoring wire core + support component spiral spacing arrangement, conductive polyethylene insulation and aramid fiber braided shielding structure, the two monitoring wire cores always remain in contact, the braided layer effectively shields vehicle electromagnetic interference, and the monitoring wire core quickly conducts the trigger signal when coolant leaks, without false alarms caused by mechanical contact and electromagnetic interference, the monitoring response time is ≤0.5s, which greatly improves the charging safety protection level; (2) By setting the thread insulation to a continuous equidistant thread structure, the thread structure can freely expand and contract when bent, avoiding the problems of wrinkles, flattening and flow reduction of traditional round tube insulation. The bending radius of the cable is reduced by more than 30%, and the bending life is increased by 50%, making it suitable for frequent dragging and winding usage scenarios. (3) By using the threaded insulation layer as a cooling channel, the independent cooling pipe is eliminated, and the insulation and liquid cooling channel are integrated into a design. The outer diameter of the cable is reduced by 20% and the weight is reduced by 25%. It is lighter and easier to use under high current transmission, and the user's operating experience is improved. (4) High-temperature resistant fluoroplastics are used for thread insulation and return pipe, and the material performance indicators are strictly limited. After aging in hot air at 260℃ for 7 days and soaking in coolant at 150℃ for 7 days, the tensile strength and elongation at break retention rate are ≥70%, and the swelling rate is ≤10%, which avoids material swelling, cracking and performance degradation under high temperature medium and extends the service life to more than 8 years. (5) By setting the control cable core group as a twisted shield unit and optimizing the twisted pitch, electromagnetic interference during the charging process is effectively suppressed, ensuring stable transmission of communication and control signals and adapting to the high-precision signal transmission requirements under high voltage and high current. (6) The problem of easy deviation and jamming of the inner conductor of the threaded insulation is solved by the wire rope traction threading process. By limiting the key parameters such as the cable pitch of the monitoring unit, the extrusion temperature and pressure of the sheath, large-scale stable production is achieved, the product size, performance and structure are highly consistent, and the yield rate is greatly improved. (7) By using lubricated wrapping paper wrapping and extrusion sheath extrusion, the cable friction loss is reduced, the sheath is closely fitted with the internal structure, and the cable's tensile strength, tear resistance and wear resistance are improved, making it suitable for complex vehicle and charging pile usage environments. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the monitoring core structure in this invention.

[0021] In the diagram: 1. Leakage monitoring unit, 11. Monitoring core, 111. Monitoring conductor, 112. Monitoring insulation, 113. Braided shield, 12. Support component, 2. Composite cable core, 21. Ground core, 211. Ground conductor, 212. Ground insulation, 22. Control cable core assembly, 221. Control conductor, 222. Control insulation, 23. Power core, 231. Power conductor, 232. Cooling channel, 233. Threaded insulation, 24. Return pipe, 3. Wrapping layer, 4. Sheath. Detailed Implementation

[0022] 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.

[0023] 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.

[0024] Figure 1 and Figure 2The cable shown is a high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles. From the inside out, it consists of a leakage monitoring line 1, a cable core 2, a wrapping layer 3, and a sheath 4. The cable core includes a ground core 21, a control core group 22, a power core 23, and a return pipe 24. The leakage monitoring line 1 includes a monitoring core 11, a monitoring conductor 111, a monitoring insulation 112, a braided shield 113, and a support member 12. The ground core 21 includes a ground conductor 211 and a ground insulation 212. The control core group 22 includes a control conductor 221 and a control insulation 222. The power core 23 includes a power conductor 231, a cooling channel 232, and threaded insulation 233. The leakage detection line 1 is positioned between the ground core 21 and the power core 23. Two detection cores 11 and two support members 12 are provided. The detection cores 11 are located in the gap between the two support members 12, and the two detection cores do not contact each other. The detection cores 11 and support members 12 are arranged spirally. The monitoring insulation 112 is made of conductive polyethylene, and a braided shield 113 is provided outside the monitoring insulation 112. The braided shield 113 is made of PP fiber or aramid fiber. The control core group 22 consists of at least four control cores, which can be divided into multiple unit control core pairs positioned between the ground core 21, the power core 23, and the return pipe 24. The cooling channel 232 and the return pipe 24 are circulated with cooling liquid, which can be water, a mixture of water and ethylene glycol, a mixture of water and propylene glycol, etc. The threaded insulation 235 is a continuous thread, with a spacing of 1-5 mm between the inner side of the thread trough and the outer side of the thread crest. The core conductor 231 and the threaded insulation 233 form a cooling channel 232. The threaded insulation 233 and the return pipe 24 are made of fluoroplastic, meeting the requirements of retaining ≥70% of tensile strength and elongation at break after 7 days of aging in hot air at 260℃, and retaining ≥70% of tensile strength and elongation at break after immersion in cooling liquid at 150℃ for 7 days, with a swelling rate ≤10%. The wrapping layer 3 is made of lubricating wrapping paper with an overlap rate of 10%-30%. The sheath 4 is made of TPU material.

[0025] The manufacturing process includes the following steps: Step 1: Determine the cable structure; Step 2: Fabricate the leakage monitoring line 1; Step 3: Fabricate the ground conductor 211, control conductor 221, and power conductor 231; Step 4: Fabricate the threaded insulation 233 and return tube 24; Step 5: Extrude the ground insulation 212 from the ground conductor 211, and extrude the control insulation 222 from the control conductor 221; Step 6: Perform irradiation crosslinking on the ground insulation 212 and control insulation 222; Step 7: Insert the threaded insulation 231 into the threaded insulation 233; Step 8: Separate the control cable cores into cabling groups to form control core pairs; Step 9: Assemble the leakage monitoring line 1, ground core 21, control core group 22, power core 23, and return tube 24 into a cable and wrap it with the sheath 3; Step 10: Extrude the sheath 4 from the sheath 3.

[0026] In step two, the method for making the leakage monitoring line 1 is as follows: first, make the monitoring conductor 111, then extrude the monitoring insulation 112 from the monitoring conductor 111, then make the braided shield 113 on the outside of the monitoring insulation 112 to make the monitoring core 11. Two support members 12 and two monitoring cores 11 are arranged in a cable at intervals, and the cable pitch is 10 to 30 times the outer diameter of the total cable.

[0027] In step seven, a 2mm diameter steel wire rope is first threaded into the threaded insulation 233 using a threading machine, then the power conductor 231 is connected to the steel wire rope, and finally pulled into the threaded insulation 233.

[0028] The eleventh step, extruding the sheath 4, is produced by extrusion at an extrusion temperature of 175°C.

[0029] 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 highly flexible liquid-cooled high-power monitoring cable for new energy vehicles, characterized in that, From the inside out, it includes a leakage monitoring unit (1), a composite cable core (2), a wrapping layer (3), and a sheath (4); the composite cable core (2) includes a ground core (21), a control cable core group (22), a power core (23), and a return pipe (24); the power core (23) includes a power conductor (231), a cooling channel (232), and threaded insulation (233); the leakage monitoring unit (1) includes a monitoring core (11) and a support member (12); The leakage monitoring unit (1) includes two monitoring wire cores (11) and two support members (12). The monitoring wire cores (11) and the support members (12) are spirally twisted at intervals, and the two monitoring wire cores (11) do not contact each other. The monitoring wire cores (11) are, from the inside to the outside, a monitoring conductor (111), a monitoring insulation (112), and a braided shield (113). The thread insulation (233) is a continuous equidistant thread structure, with a distance of 1~5mm between the inner side of the thread trough and the outer side of the thread crest, and a uniform wall thickness deviation of ≤0.1mm. The control cable core group (22) consists of a twisted pair shielding unit composed of no less than 4 control conductors (221), and the twisted pair pitch is 8 to 12 times the outer diameter of the core.

2. The high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles according to claim 1, characterized in that, The monitoring insulation (112) is made of conductive polyethylene, and the braided shield (113) is made of aramid fiber braided layer with a braiding density of ≥85%.

3. The high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles according to claim 1, characterized in that, The threaded insulation (233) and return pipe (24) are made of fluoroplastic. After aging in hot air at 260°C for 7 days and soaking in coolant at 150°C for 7 days, the tensile strength and elongation at break retention rates are both ≥70%, and the swelling rate is ≤10%.

4. The high-flexibility liquid-cooled high-power monitoring cable for new energy vehicles according to claim 1, characterized in that, The wrapping layer (3) is a lubricating wrapping paper with an overlap rate of 10%~30%; the sheath (4) is a weather-resistant TPU material with a Shore hardness of 85~95A.

5. A manufacturing process for a highly flexible liquid-cooled high-power monitoring cable for new energy vehicles, characterized in that, Includes the following steps: Step 1: Determine the cable structure as described in claim 1; Step 2: Prepare the leakage monitoring unit (1); Step 3: Draw the ground conductor (211), control conductor (221), and power conductor (231); Step 4: Extrude and form threaded insulation (233) and return tube (24); Step 5: Extrude the ground insulation (212) and control insulation (222) and irradiate them for crosslinking; Step 6: Use steel wire rope to pull the power conductor (231) through the threaded insulation (233); Step 7: Twist the control cable core group (22) into a cable; Step 8: Assemble the leakage monitoring unit (1), ground core (21), control cable core group (22), power core (23), and return tube (24) into a cable and wrap it with a sheath (3); Step 9: Extrude and form a sheath (4).

6. The production process according to claim 5, characterized in that, In step two, the cable pitch of the leakage monitoring unit (1) is 10 to 30 times the outer diameter of the total cable; in step six, the diameter of the wire rope is 2 mm, and the threading tension is constant ≤50N.

7. The production process according to claim 5, characterized in that, In step nine, the sheath (4) is extruded by extrusion, with an extrusion temperature of 170~180℃ and an extrusion pressure of 0.8~1.2MPa.

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