A high-power charging gun line and connector integrated liquid cooling heat dissipation structure

Abstract

The present application relates to new energy automobile charging equipment technical field, specifically for a kind of high-power charging gun line and connector integration liquid cooling heat dissipation structure;The present application is embedded to underground constant temperature layer by supporting frame, and insulation temperature-resistant coolant is realized reciprocating circulation by connecting pipe into circulating pump, cooling liquid flows into heat exchange pipeline in turn by return liquid pipe, plug-in connecting piece one, insulation temperature-resistant coolant is heat-exchanged and cooled by using underground constant temperature layer after temperature rise;By being fixed in the inner wall of charging cabinet, the terminal inner cavity is provided with spiral airtight cooling cavity and is assembled with distributed micro-channel gun line body, relies on seamless pressure joint to reduce contact resistance to reduce heat from source;Control box drives insulation temperature-resistant coolant to circulate heat absorption and heat dissipation in the terminal cooling cavity and the insulation micro-cooling pipe spirally arranged in cable, simultaneously with the aid of bimetallic strip type thermal sensitive regulating valve, cooling liquid flow is self-adaptingly regulated according to real-time temperature, realize full-condition adaptation, give consideration to heat dissipation effect and energy-saving characteristics.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle charging equipment technology, specifically to an integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector. Background Technology

[0002] Currently, high-power DC fast charging piles can operate at currents exceeding 200A. Traditional charging gun connectors and cables rely on natural heat dissipation, which presents several technical drawbacks. Firstly, the conductors and terminals are connected via bolts or conventional crimping, resulting in high contact resistance. Under high current conditions, this easily leads to localized hot spots and excessive temperature rise. Secondly, the dense arrangement of cable cores limits internal heat dissipation space, causing heat to accumulate easily. Prolonged exposure to high temperatures accelerates insulation aging and shortens product lifespan. Furthermore, its heat dissipation capacity cannot adaptively adjust to changes in ambient temperature and load current, posing significant safety hazards under heavy loads and high summer temperatures. Existing devices require additional cooling equipment such as fans to dissipate heat from charging devices. However, the added cooling equipment itself generates heat, further reducing heat dissipation efficiency and causing poor cooling effect.

[0003] Therefore, a high-power charging gun cable and connector integrated liquid cooling structure is needed to improve the above problems. Summary of the Invention

[0004] To address the shortcomings of existing technologies in the use of integrated liquid cooling structures for high-power charging gun cables and connectors, such as excessive temperature rise, uneven heat dissipation, and lack of adaptive adjustment, this invention provides an integrated liquid cooling structure for high-power charging gun cables and connectors to solve the aforementioned problems.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A high-power charging gun cable and connector integrated liquid cooling heat dissipation structure includes a charging cabinet, a control box is embedded in the outer wall of the charging cabinet, a control panel is embedded in the outer wall of the charging cabinet, a charging gun mounting base is fixedly installed directly below the control panel and on the outer wall of the charging cabinet, a charging gun body is plugged into the outer wall of the charging gun mounting base, and a cable outlet groove is provided on the bottom outer wall of the charging cabinet. The inner wall of the charging cabinet is equipped with a heat dissipation component for liquid cooling, and a constant temperature control component for low-energy temperature regulation of the liquid coolant.

[0006] As a preferred embodiment of the present invention, the heat dissipation component includes a liquid-cooled conductive terminal, which is fixedly installed on the inner wall of the charging cabinet. The front end of the liquid-cooled conductive terminal is a plug-in end, and the rear end of the liquid-cooled conductive terminal is a crimp end. A spiral-type sealed cooling chamber is opened in the inner cavity of the liquid-cooled conductive terminal. A distributed microchannel gun wire body is fixedly installed on the crimp end of the liquid-cooled conductive terminal. Power wire cores are evenly arranged along the circumference on the inner wall of the distributed microchannel gun wire body.

[0007] As a preferred embodiment of the present invention, multiple sets of power cores are equidistantly embedded with insulating micro-cooling tubes. The insulating micro-cooling tubes are located in the inner cavity of the distributed microchannel gun wire body. The insulating micro-cooling tubes are arranged in a spiral direction along the length of the cable, and a tail return pipe is provided at one end of the insulating micro-cooling tube. The other end of the insulating micro-cooling tube is connected to the spiral sealed cooling cavity of the liquid-cooled conductive terminal.

[0008] As a preferred embodiment of the present invention, the plug-in end of the liquid-cooled conductive terminal is equipped with a connector, and a bimetallic strip thermal regulating valve is provided on the outer wall of the connector. One end of the bimetallic strip thermal regulating valve is fixedly connected to a miniature silent water pump through a conduit, and the miniature silent water pump is fixedly connected to a coolant tank through inlet and outlet pipes.

[0009] As a preferred embodiment of the present invention, the constant temperature control component includes an electromagnetic flow valve, which is fixedly installed on the side wall of the coolant tank through an inlet pipe. A circulation pump is fixedly installed at one end of the electromagnetic flow valve through a connecting pipe, and a return pipe is fixedly installed at one end of the circulation pump. A temperature sensor is embedded in the outer wall of the return pipe.

[0010] As a preferred embodiment of the present invention, the sensing end of the temperature sensor extends to the inner wall of the return pipe, one end of the return pipe is fixedly installed with a heat exchange pipeline via a plug-in connector, a support frame is fixedly connected to the outer wall of the heat exchange pipeline, one end of the heat exchange pipeline is fixedly installed with an inlet pipe via a plug-in connector, and an electromagnetic flow valve is fixedly connected to the inlet pipe.

[0011] As a preferred embodiment of the present invention, the bimetallic strip thermostatic regulating valve adjusts according to the real-time temperature. When the temperature rises, the bimetallic strip thermostatic regulating valve automatically opens the valve port to increase the coolant flow rate; when the temperature drops, the bimetallic strip thermostatic regulating valve automatically reduces the flow rate.

[0012] As a preferred embodiment of the present invention, the inner cavity of the coolant tank is provided with an insulating and temperature-resistant coolant. The coolant is selected as an insulating medium that can withstand 125°C. The control box is connected to a control panel, a miniature silent water pump, an electromagnetic flow valve, a circulation pump, and a temperature sensor via wires, and the connection method is electrical connection.

[0013] Compared with the prior art, the present invention fixes the liquid-cooled conductive terminal to the inner wall of the charging cabinet. The terminal is provided with a plug end and a crimp end, and its inner cavity has a spiral sealed cooling chamber. The crimp end is assembled with the distributed microchannel gun wire body. With the help of the seamless crimping structure of the conductor and the terminal, the contact resistance can be significantly reduced, thereby reducing heat generation from the source.

[0014] This invention controls the circulation of insulating and heat-resistant coolant through a control box. Multiple sets of power cores are equidistantly embedded with insulating micro-cooling tubes. These cooling tubes are arranged inside the distributed microchannel gun wire body and spiral along the length of the cable. The heat generated by the power cores when energized can be absorbed by the insulating and heat-resistant coolant flowing inside the tubes. One end of the insulating micro-cooling tube is connected to the tail return pipeline for coolant return, and the other end is connected to the spiral sealed cooling chamber of the liquid-cooled conductive terminal, so that the insulating and heat-resistant coolant circulates in the entire pipeline, achieving liquid cooling heat dissipation.

[0015] This invention utilizes an insulating and heat-resistant coolant that is returned through a tail-end return pipe. The coolant then circulates within the pipe for liquid cooling. When the coolant passes through a bimetallic thermostatic regulating valve, the valve adjusts according to the real-time temperature. When the temperature rises, the valve automatically opens wider, increasing the coolant flow rate; when the temperature drops, the valve automatically reduces the flow rate. This adaptive flow control is energy-saving and adaptable to all operating conditions.

[0016] This invention completes the pre-embedded installation by embedding the support frame into the underground constant temperature layer and arranging the heat exchange pipelines on the inner wall of the support frame before backfilling. The control panel is activated and preset parameters are set. The control panel outputs an electrical signal to the control box, which drives the electromagnetic flow valve, circulation pump, and temperature sensor. After the electromagnetic flow valve opens, the insulating heat-resistant coolant enters the circulation pump through the connecting pipe, achieving reciprocating circulation. The coolant flows sequentially through the return pipe and the plug-in connector into the heat exchange pipeline. The underground constant temperature layer cools the heated insulating heat-resistant coolant. The cooled insulating heat-resistant coolant then flows back to the coolant tank through the inlet pipe. This solves the problem of needing additional cooling equipment such as fans, which would generate heat themselves, further reducing heat dissipation efficiency and resulting in poor cooling. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the heat dissipation component structure of the present invention; Figure 3 For the present invention Figure 2 Enlarged schematic diagram of the structure at point A; Figure 4 For the present invention Figure 2 Enlarged schematic diagram of the structure at point B; Figure 5 This is a side view of the structure of the present invention; Figure 6 For the present invention Figure 5 Enlarged schematic diagram of the structure at point C; Figure 7 For the present invention Figure 5 A magnified schematic diagram of the structure at point D.

[0018] In the diagram: 1. Charging cabinet; 2. Control box; 3. Control panel; 4. Charging gun mounting base; 5. Charging gun body; 6. Cable outlet; 7. Heat dissipation assembly; 701. Liquid-cooled conductive terminal; 702. Spiral sealed cooling chamber; 703. Distributed microchannel cable body; 704. Power core; 705. Insulated micro-cooling tube; 706. Tail return pipe; 707. Connecting device; 708. Bimetallic thermistor valve; 709. Miniature silent water pump; 710. Inlet and outlet pipes; 711. Coolant tank; 8. Thermostatic control assembly; 801. Electromagnetic flow valve; 802. Inlet pipe; 803. Connecting pipe; 804. Circulation pump; 805. Return pipe; 806. Temperature sensor; 807. Plug-in connector one; 808. Heat exchange pipe; 809. Support frame; 810. Plug-in connector two; 811. Inlet pipe. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] Example: Please refer to Figure 1-7 The high-power charging gun cable and connector integrated liquid cooling heat dissipation structure shown includes a charging cabinet 1, a control box 2 embedded in the outer wall of the charging cabinet 1, a control panel 3 embedded in the outer wall of the charging cabinet 1, a charging gun mounting base 4 fixedly installed directly below the control panel 3 and on the outer wall of the charging cabinet 1, a charging gun body 5 plugged into the outer wall of the charging gun mounting base 4, and a cable outlet groove 6 opened on the bottom outer wall of the charging cabinet 1. The inner wall of the charging cabinet 1 is equipped with a heat dissipation component 7 for liquid cooling, and a constant temperature control component 8 for low-energy temperature regulation of the liquid coolant.

[0021] In this embodiment, specific references Figure 1 , Figure 2 , Figure 3 , Figure 5 , Figure 6 and Figure 7 The heat dissipation component 7 includes a liquid-cooled conductive terminal 701, which is fixedly installed on the inner wall of the charging cabinet 1. The front end of the liquid-cooled conductive terminal 701 is a plug-in end, and the rear end is a crimp end. A spiral-shaped sealed cooling chamber 702 is formed in the inner cavity of the liquid-cooled conductive terminal 701. A distributed microchannel gun wire body 703 is fixedly installed on the crimp end of the liquid-cooled conductive terminal 701. Power wire cores 704 are evenly arranged along the circumference on the inner wall of the distributed microchannel gun wire body 703. Insulated micro-cooling tubes 705 are embedded equidistantly between multiple sets of power wire cores 704. The insulated micro-cooling tubes 705 are located in the distributed microchannel gun wire body 703. The inner cavity has an insulated miniature cooling tube 705 arranged in a spiral pattern along the length of the cable. One end of the insulated miniature cooling tube 705 is provided with a tail return pipe 706. The other end of the insulated miniature cooling tube 705 is connected to the spiral sealed cooling chamber 702 of the liquid-cooled conductive terminal 701. The plug-in end of the liquid-cooled conductive terminal 701 is fitted with a connector 707. A bimetallic strip thermal regulating valve 708 is provided on the outer wall of the connector 707. One end of the bimetallic strip thermal regulating valve 708 is fixedly connected to a miniature silent water pump 709 through a conduit. The miniature silent water pump 709 is fixedly connected to a coolant tank 711 through an inlet / outlet liquid pipe 710.

[0022] In this embodiment, specific references Figure 1 , Figure 2 , Figure 4 , Figure 5 and Figure 7 The thermostatic control component 8 includes an electromagnetic flow valve 801, which is fixedly installed on the side wall of the coolant tank 711 via an inlet pipe 802. A circulation pump 804 is fixedly installed at one end of the electromagnetic flow valve 801 via a connecting pipe 803. A return pipe 805 is fixedly installed at one end of the circulation pump 804. A temperature sensor 806 is embedded in the outer wall of the return pipe 805. The sensing end of the temperature sensor 806 extends to the inner wall of the return pipe 805. A heat exchange pipe 808 is fixedly installed at one end of the return pipe 805 via a plug-in connector 807. A support frame 809 is fixedly connected to the outer wall of the heat exchange pipe 808. An inlet pipe 811 is fixedly installed at one end of the heat exchange pipe 808 via a plug-in connector 810. The electromagnetic flow valve 801 is fixedly connected to the inlet pipe 811.

[0023] Among them, the bimetallic strip thermal regulating valve 708 adjusts according to the real-time temperature. When the temperature rises, the bimetallic strip thermal regulating valve 708 automatically opens the valve port and increases the coolant flow rate; when the temperature drops, the bimetallic strip thermal regulating valve 708 automatically reduces the flow rate.

[0024] Based on the above structural features and connection relationships, the circulating pump 804 circulates the insulating heat-resistant coolant repeatedly, allowing the insulating heat-resistant coolant to flow into the heat exchange pipeline 808 through the return pipe 805 and the plug-in connector 807 for heat exchange. This allows the heated insulating heat-resistant coolant to enter the underground constant temperature layer for cooling. Subsequently, when the cooled insulating heat-resistant coolant flows back to the coolant tank 711 through the inlet pipe 811, the temperature sensor 806 will generate data on the temperature of the inner wall of the return pipe 805. This will cause the temperature sensor 806 to generate an electrical signal, which will be transmitted to the control box 2 through the wire for monitoring. The coolant tank 711 contains an insulating and temperature-resistant coolant, which is a medium resistant to 125℃. The control box 2 is electrically connected to the control panel 3, the miniature silent water pump 709, the electromagnetic flow valve 801, the circulation pump 804, and the temperature sensor 806 via wires. This connection enables the device to be powered on, thereby allowing the control box 2 to control the operation of the control panel 3, the miniature silent water pump 709, the electromagnetic flow valve 801, the circulation pump 804, and the temperature sensor 806.

[0025] In this solution, the integrated liquid-cooled heat dissipation structure of the high-power charging gun cable and connector works by fixing the liquid-cooled conductive terminal 701 on the inner wall of the charging cabinet 1. The front end of the liquid-cooled conductive terminal 701 is the plug-in end, and the rear end of the liquid-cooled conductive terminal 701 is the crimp end. A spiral-type sealed cooling cavity 702 is opened in the inner cavity of the liquid-cooled conductive terminal 701. Then, the distributed microchannel gun cable body 703 is fixedly installed on the crimp end of the liquid-cooled conductive terminal 701. Since the conductor and terminal are seamlessly crimped, the contact resistance is greatly reduced, reducing heat generation from the source. This solves the problem that when the conductor and terminal are connected by bolts or conventional crimping methods, the contact resistance is large, and local hot spots are easily formed under high current conditions, causing the temperature rise to exceed the standard. By turning on the switch of the control panel 3, an electrical signal is generated and transmitted to the control box 2 via wires. This causes the control box 2 to control the operation of the insulating high-temperature resistant coolant. Because multiple sets of power cores 704 are equidistantly embedded with insulating micro-cooling tubes 705, and because these micro-cooling tubes 705 are located among the power cores 704, when the power cores 704 are energized and generate heat, the insulating high-temperature resistant coolant flowing inside the insulating micro-cooling tubes 705 absorbs heat. Simultaneously, the insulating micro-cooling tubes 705 are located within the inner cavity of the distributed microchannel gun wire body 703, and the insulating micro-cooling tubes... The cooling pipe 705 is arranged in a spiral pattern along the length of the cable, and a tail return pipe 706 is provided at one end of the insulating miniature cooling pipe 705, so that the insulating heat-resistant coolant can return through the tail return pipe 706. The other end of the insulating miniature cooling pipe 705 is connected to the spiral sealed cooling chamber 702 of the liquid-cooled conductive terminal 701, which allows the insulating heat-resistant coolant to circulate in the pipe for liquid cooling heat dissipation. This solves the problem that the cable core is densely arranged, the internal heat dissipation space is limited, heat is easy to accumulate, and long-term high temperature environment will accelerate the aging of the insulation layer and shorten the service life of the product. The insulating and heat-resistant coolant is returned through the tail return pipe 706, and then circulates in the pipe for liquid cooling. When the insulating and heat-resistant coolant passes through the bimetallic thermostatic regulating valve 708, the bimetallic thermostatic regulating valve 708 will adjust according to the real-time temperature. When the temperature rises, the bimetallic thermostatic regulating valve 708 automatically opens the valve port and increases the coolant flow rate; when the temperature drops, the bimetallic thermostatic regulating valve 708 automatically reduces the flow rate. The temperature control valve adaptively adjusts the flow rate, which is energy-saving and adaptable to all working conditions. This solves the problem that the heat dissipation capacity cannot be adaptively adjusted with changes in ambient temperature and load current, which poses a significant safety hazard under heavy load and high summer temperatures. The support frame 809 is pre-embedded in the underground constant temperature layer. Then, the heat exchange pipes 808 are arranged on the inner wall of the support frame 809 and backfilled for installation. The control panel 3 is then turned on with preset parameters, causing it to generate an electrical signal that is transmitted to the control box 2 via wires. This causes the control box 2 to control the operation of the electromagnetic flow valve 801, the circulating pump 804, and the temperature sensor 806. The electromagnetic flow valve 801 opens, allowing the insulating, high-temperature resistant coolant to flow through the connecting pipe 803 into the circulating pump 804, which then circulates... Pump 804 circulates the insulating heat-resistant coolant repeatedly, allowing it to flow through return pipe 805 and plug-in connector 807 into heat exchange pipe 808 for heat exchange. This allows the heated insulating heat-resistant coolant to enter the underground constant temperature layer for cooling. Subsequently, the cooled insulating heat-resistant coolant flows back to coolant tank 711 through inlet pipe 811. This solves the problem of additional cooling equipment such as fans, which would generate heat and further reduce heat dissipation efficiency and cooling effect.

[0026] The control panel 3, miniature silent water pump 709, electromagnetic flow valve 801, temperature sensor 806, circulation pump 804, and control box 2 used in this invention are all existing known electrical devices, and all can be directly purchased and used on the market. Their structure, circuit, and control principle are all existing known technologies. Therefore, the structure, circuit, and control principle of the control panel 3, miniature silent water pump 709, electromagnetic flow valve 801, circulation pump 804, temperature sensor 806, and control box 2 will not be described in detail here.

[0027] All standard parts used in this application can be purchased from the market. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art and are also general components, which are common knowledge in this field.

[0028] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-power charging gun cable and connector integrated liquid cooling heat dissipation structure, comprising a charging cabinet (1), characterized in that: A control box (2) is embedded in the outer wall of the charging cabinet (1). A control panel (3) is embedded in the outer wall of the charging cabinet (1). A charging gun mounting base (4) is fixedly installed directly below the control panel (3) and on the outer wall of the charging cabinet (1). A charging gun body (5) is plugged into the outer wall of the charging gun mounting base (4). A cable outlet groove (6) is opened on the bottom outer wall of the charging cabinet (1). The inner wall of the charging cabinet (1) is provided with a heat dissipation component (7) for liquid cooling, and the inner wall of the charging cabinet (1) is provided with a constant temperature control component (8) for low-energy temperature control of the liquid coolant.

2. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 1, characterized in that: The heat dissipation component (7) includes a liquid-cooled conductive terminal (701), which is fixedly installed on the inner wall of the charging cabinet (1). The front end of the liquid-cooled conductive terminal (701) is a plug-in end, and the rear end of the liquid-cooled conductive terminal (701) is a crimp end. The inner cavity of the liquid-cooled conductive terminal (701) is provided with a spiral sealed cooling cavity (702). The crimp end of the liquid-cooled conductive terminal (701) is fixedly installed with a distributed microchannel gun wire body (703). The inner wall of the distributed microchannel gun wire body (703) is uniformly provided with power wire cores (704) along the circumference.

3. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 2, characterized in that: Multiple sets of power cores (704) are equidistantly embedded with insulating micro-cooling tubes (705). The insulating micro-cooling tubes (705) are located in the inner cavity of the distributed microchannel gun wire body (703). The insulating micro-cooling tubes (705) are arranged in a spiral direction along the length of the cable. A tail return pipe (706) is provided at one end of the insulating micro-cooling tube (705). The other end of the insulating micro-cooling tube (705) is connected to the spiral sealed cooling cavity (702) of the liquid-cooled conductive terminal (701).

4. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 2, characterized in that: The plug-in end of the liquid-cooled conductive terminal (701) is plugged in and installed with a connector (707). A bimetallic strip thermosensitive regulating valve (708) is provided on the outer wall of the connector (707). One end of the bimetallic strip thermosensitive regulating valve (708) is fixedly connected to a miniature silent water pump (709) through a conduit. The miniature silent water pump (709) is fixedly connected to a coolant tank (711) through an inlet and outlet liquid pipeline (710).

5. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 4, characterized in that: The constant temperature control component (8) includes an electromagnetic flow valve (801), which is fixedly installed on the side wall of the coolant tank (711) via an inlet pipe (802). A circulation pump (804) is fixedly installed at one end of the electromagnetic flow valve (801) via a connecting pipe (803). A return pipe (805) is fixedly installed at one end of the circulation pump (804). A temperature sensor (806) is embedded in the outer wall of the return pipe (805).

6. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 5, characterized in that: The sensing end of the temperature sensor (806) extends to the inner wall of the return pipe (805). One end of the return pipe (805) is fixedly installed with a heat exchange pipe (808) via a plug-in connector (807). A support frame (809) is fixedly connected to the outer wall of the heat exchange pipe (808). One end of the heat exchange pipe (808) is fixedly installed with an inlet pipe (811) via a plug-in connector (810). An electromagnetic flow valve (801) is fixedly connected to the inlet pipe (811).

7. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 4, characterized in that: The bimetallic thermostatic regulating valve (708) adjusts according to the real-time temperature. When the temperature rises, the bimetallic thermostatic regulating valve (708) automatically opens the valve port and increases the coolant flow rate; when the temperature drops, the bimetallic thermostatic regulating valve (708) automatically reduces the flow rate.

8. The integrated liquid-cooled heat dissipation structure for a high-power charging gun cable and connector according to claim 6, characterized in that: The inner cavity of the coolant tank (711) is equipped with an insulating and temperature-resistant coolant. The coolant is an insulating medium that can withstand 125℃. The control box (2) is connected to the control panel (3), the miniature silent water pump (709), the electromagnetic flow valve (801), the circulation pump (804), and the temperature sensor (806) via wires, and the connection method is electrical connection.

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