High-toughness cable

Abstract

The utility model relates to the field of cables, in particular to a high-toughness cable, which is applied to an electric automobile charging pile and comprises a cable core and a protective layer coated outside the cable core, the cable core comprises a current line, a signal transmission line and an elastic steel cable, and the current line, the signal transmission line and the elastic steel cable are tightly twisted to form the cable core. Wherein the elastic steel cable is used for enabling the high-toughness cable to have a telescopic effect similar to that of a spring. After being stretched, bent and used for multiple times, the elastic steel cable still has very good elasticity and toughness, and can well cope with the occasion of repeated bending and stretching in the using process of the electric vehicle charging pile. In the processing process, the elastic steel cable is molded and fixed once according to the shape and the size required by a finished cable when being drawn out, and the high-toughness cable is manufactured after the elastic steel cable is completely cooled, so that the working procedures and the manual operation time are reduced, the potential safety hazard is reduced, and the safety and the reliability of the charging behavior of the electric vehicle are greatly improved.

Description

Technical Field

[0001] The utility model relates to the field of cables, in particular to a high-toughness cable. Background Art

[0002] Cables are used to transmit electricity, signals or data. They are made of multiple strands of wires or insulated wires twisted together. They are usually used in construction, electrical engineering, communications and other fields. With the vigorous development of electric vehicles, cables are used as carriers to connect electric vehicles and charging piles. The market demand is increasing, and the corresponding performance requirements are also getting higher and higher. The traditional cables for electric vehicle charging piles, also known as spring cables, are made by heating the finished cables at high temperatures and curling them on a cylindrical heating device. The outer sheath of the cable and the conductor in the cable are subjected to secondary plasticization by continuous heating, so as to achieve a retractable effect similar to a spring. However, the outer sheath of the cable made by this heating and curling process has undergone a high-temperature treatment in the process of preparing the finished cable, and the outer sheath of the cable has undergone a secondary high-temperature plasticization in the process of plasticization, which will accelerate the aging and rupture of the outer sheath of the cable, triggering leakage events, and posing certain safety hazards. In addition, the current spring cables have been stretched for a long time, and the elasticity will decrease rapidly due to the high temperature, sunshine, wind and rain in the external environment, until they have no elasticity and are scrapped. It can be seen that most of the spring cables on the market are not able to cope well with the repeated bending and stretching during the use of electric vehicle charging piles, which will further reduce the charging quality and service life of electric vehicle charging piles. All of the above problems need to be solved urgently. Utility Model Content

[0003] In view of this, the utility model proposes a high-toughness cable, which aims to solve the problem that the existing cables for electric vehicle charging piles have low bending resistance and cannot cope well with the use environment, and also have certain safety hazards.

[0004] The utility model proposes a high-toughness cable, which is applied to an electric vehicle charging pile, comprising a cable core and a protective layer coated on the outside of the cable core. The cable core comprises a current line, a signal transmission line and an elastic steel cable. The current line, the signal transmission line and the elastic steel cable are tightly twisted into the cable core.

[0005] Furthermore, the retractable length range of the elastic steel cable is 85%-95% of the overall length of the elastic steel cable.

[0006] Furthermore, the elastic steel cable includes a first elastic steel cable, a second elastic steel cable and a third elastic steel cable, and the first elastic steel cable, the second elastic steel cable, the third elastic steel cable, the current line and the signal transmission line are tightly twisted into the cable core.

[0007] Furthermore, the current line includes a ground line, a phase line and a neutral line capable of passing a voltage of at least 500V, and the ground line, the phase line and the neutral line are all covered with an insulating layer.

[0008] Furthermore, the phase line is an AC power phase line, and the signal transmission line is a pure copper conductor.

[0009] Furthermore, the protective layer includes a wrapping layer for supporting the cable core.

[0010] Furthermore, the wrapping layer is a cotton paper layer or a non-woven fabric layer.

[0011] Furthermore, the protective layer also includes an outer sheath layer coated on the outside of the wrapping layer for insulating and protecting the internal cable core.

[0012] Furthermore, the outer layer is a polyvinyl chloride layer, a thermoplastic elastomer layer or a polyurethane layer.

[0013] Furthermore, the high-toughness cable is a cylindrical cable, and its two ends are straight and its middle is a spiral ring.

[0014] Compared with the prior art, the beneficial effects of the utility model are: a high-toughness cable, applied to electric vehicle charging piles, comprising a cable core and a protective layer covering the outside of the cable core, the cable core comprising a current line, a signal transmission line and an elastic steel cable, the current line, the signal transmission line and the elastic steel cable are tightly twisted into the cable core. Among them, the current line is used to transmit electricity, the signal transmission line is used to transmit detection signal nodes and voltage / current signals, and the elastic steel cable is used to make the high-toughness cable have a spring-like expansion and contraction effect. The elastic steel cable has the characteristics of high toughness, strong resilience and long life. Compared with conventional spring cables, after multiple stretching and bending, the elastic steel cable still has very good elasticity and toughness, and will not lose elasticity due to long-term use. It can well cope with the repeated bending and stretching during the use of electric vehicle charging piles. During the processing, the elastic steel cable is shaped and fixed once according to the required shape and size of the finished cable when it is drawn out. After being completely cooled, the high-toughness cable is made. There is no need to carry out the heating and curling process required for conventional spring cables. This not only reduces the process and manual operation time, but also reduces safety hazards, greatly improving the safety and reliability of electric vehicle charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] By reading the detailed description of the preferred embodiment below, various other advantages and benefits will become clear to those of ordinary skill in the art. The accompanying drawings are only used for the purpose of illustrating the preferred embodiment and are not considered to be limiting of the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0016] Figure 1 A cross-sectional view of a high-toughness cable provided by an embodiment of the utility model;

[0017] Figure 2 A schematic diagram of the structure of a high-toughness cable provided by an embodiment of the utility model;

[0018] Figure 3 A schematic structural diagram of a high-toughness cable from another perspective provided in an embodiment of the utility model.

[0019] Description of Figure Numbers:

[0020] 101--AC power phase line, 102-signal transmission line, 103-first elastic steel cable, 104-ground line, 105-second elastic steel cable, 106-neutral line, 107-third elastic steel cable, 108-wrapping layer, 109-outer layer. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the scheme in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0022] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0023] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the utility model, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the utility model.

[0024] Please refer to Figure 1-3The utility model proposes a high-toughness cable, which is applied to electric vehicle charging piles, including a cable core and a protective layer wrapped around the outside of the cable core. The cable core includes a current line, a signal transmission line 102 and an elastic steel cable. The current line, the signal transmission line 102 and the elastic steel cable are tightly twisted into the cable core.

[0025] In this embodiment, the two ends of the high-toughness cable are respectively connected to the charging gun and the charging cabinet of the electric vehicle charging pile, and are used to transmit power to the electric vehicle to be charged and transmit detection signal nodes and voltage / current signals. It should be noted that the high-toughness cable can be used not only on the AC charging gun of the electric vehicle, but also on any high-power power-taking equipment.

[0026] Specifically, the process steps of the high-toughness cable include:

[0027] Twisted copper: Copper wires are twisted together to form the conductor portion of the cable;

[0028] Conductor coating: A layer of insulating material is coated on the twisted copper wire;

[0029] Cooling: Cool the coated conductor to facilitate subsequent processes;

[0030] Elastic steel cable stranding: Twisting the cooled conductor and elastic steel cable tightly together to increase the tensile strength and bending resistance of the cable core;

[0031] Cooling: Cool the stranded cable core to facilitate subsequent processes;

[0032] Paying off: putting the cable core into the pay-off rack, ready for the next step;

[0033] Wrapping and coating: Wrapping a layer of wrapping layer 108 around the outside of the cable core;

[0034] Outer sheath coating: an outer sheath layer 109 is coated on the outside of the wrapping layer 108 to form a finished product of the cable;

[0035] Annealing: heat treatment of the product to eliminate internal stress and improve the performance of the cable;

[0036] Painting: A layer of anti-corrosion paint is applied on the surface of the cable to prevent the cable from being corroded. In addition, a mark can be made on the outer layer 109 of the cable to identify the structure model of the cable;

[0037] Baking: Bake the painted cables to solidify the paint layer;

[0038] Cooling: Cool the baked cables to facilitate subsequent processes;

[0039] Lubrication: Apply a layer of lubricating oil on the cable surface to reduce the friction of the cable during use and form a high-toughness cable product;

[0040] Winding: Wind up the finished high-tenacity cables for packaging and transportation.

[0041] Specifically, elastic steel cables are different from conventional steel wires. The structure of elastic steel cables is relatively complex. They are made of multiple steel wires twisted together, and have good softness and large breaking force. Conventional steel wire is a kind of metal wire, which can be a single strand or multiple strands twisted together, but usually does not have such a complex structure as elastic steel cables. And elastic steel cables have high elasticity and the ability to withstand repeated stretching. The tensile strength of steel wire depends on its material and manufacturing process. The ultimate tensile strength of steel wire can have different levels, such as 1570MPa, 1670MPa, etc. In general, elastic steel cables are suitable for occasions that require elasticity and fatigue resistance, such as occasions where charging guns are frequently pulled out and retracted, while steel wires are more used to bear and buffer pressure.

[0042] Furthermore, the retractable length range of the elastic steel cable is 85%-95% of the overall length of the elastic steel cable.

[0043] In this embodiment, the elastic steel cable is the elastic source of the high-toughness cable and has high flexibility. The elastic steel cable is also called an elastic steel cable or a spring steel wire, and is a steel product with high elasticity and high strength. It is usually made of high-strength spring steel and processed by special heat treatment and cold drawing process. It has high elasticity, high strength, good fatigue resistance, corrosion resistance and high and low temperature resistance. It can well cope with long-term stretching and bending, as well as resist high temperature, sun exposure, wind and rain in the external environment.

[0044] Furthermore, the elastic steel cable includes a first elastic steel cable 103, a second elastic steel cable 105 and a third elastic steel cable 107, and the first elastic steel cable 103, the second elastic steel cable 105, the third elastic steel cable 107, the current line and the signal transmission line 102 are tightly twisted into the cable core.

[0045] In this embodiment, the number of elastic steel cables needs to be determined considering the production cost. When using multiple elastic steel cables, there is no special position requirement between the elastic steel cables, and all the elastic steel cables need to be tightly attached to and twisted together with other core wires to ensure the overall circular amplitude of the high-toughness cable. The elastic steel cable is in a spiral state after the steel cable is shaped, also known as a spiral wire, which can be customized according to the overall requirements of the high-toughness cable. The steel cable in the spiral state can withstand multiple stretching and bending, and the specific elastic force range can reach 90% of the overall length.

[0046] Furthermore, the current line includes a ground line 104 and a phase line and a neutral line 106 capable of passing a voltage of at least 500V. The ground line 104, the phase line and the neutral line 106 are all covered with an insulating layer.

[0047] In this embodiment, the phase line is the L (Live) AC power phase line 101, which is the power line, which carries power from the power source to the electric vehicle. The neutral line 106 is the N (Neutral) neutral line, which is the return line, which carries the current from the electric vehicle back to the power source. The ground line 104 is the PE (Protective Earth) protection wiring, which is used for grounding. This is a safety line, which is used to guide the current to the ground when the electrical equipment fails to prevent electric shock to the human body. The PE protection wiring is usually connected to the metal casing of the equipment so that the current can be guided to the ground when the equipment fails.

[0048] Furthermore, the phase line is an AC power phase line 101, and the signal transmission line 102 is a pure copper conductor.

[0049] In this embodiment, the phase line and the neutral line 106 need to be able to pass at least 500V voltage to assist in the charging process of the electric vehicle. The signal transmission line 102 is a pure copper wire. The signal transmission line 102 made of pure copper has high conductivity, good ductility, corrosion resistance, durability, low impedance and easy connection. Generally speaking, the pure copper wire used in the signal transmission line 102 usually refers to bare copper wire or twisted pair wire. Bare copper wire refers to a pure copper conductor without any surface treatment, which has excellent electrical conductivity. Twisted pair wires are formed by winding multiple groups of insulated copper wires with each other to transmit electrical signals internally. The design of twisted pair wires can effectively reduce electromagnetic interference, because the changing current will generate a magnetic field, and the winding method of the twisted pair wires can offset these magnetic fields to a certain extent, thereby reducing signal interference. Therefore, the application of pure copper wires in cables is mainly to provide a good signal transmission medium, using its excellent electrical conductivity to transmit electrical signals to ensure accurate and efficient transmission of signals.

[0050] Furthermore, the protective layer includes a wrapping layer 108 for supporting the cable core.

[0051] In this embodiment, the high-toughness cable is a cylindrical cable, and the internal core wires are tightly twisted together but still have some gaps. Therefore, the outer sheath 108 of the cable core can provide support for all the core wires after they are twisted together and fill these gaps, and can ensure that when the outer sheath 109 is wrapped around the outside of the cable core, it will not be squeezed into the inside of the cable core, so that it cannot be produced and processed.

[0052] Furthermore, the wrapping layer 108 is a cotton paper layer or a non-woven fabric layer.

[0053] In this embodiment, during the manufacturing process of the high-toughness cable, the wrapping layer 108 is a cotton paper layer or a non-woven fabric layer. Cotton paper layers and non-woven fabric layers are generally used as insulating, filling and protective material layers. This material layer can be used as an insulating material in the cable to prevent current leakage and ensure safe use. There may be gaps between the multiple core wires inside the cable, and these gaps can be filled with cotton paper or non-woven fabrics to make the internal structure of the cable more compact and improve its compression resistance. The cotton paper layer and the non-woven fabric layer can also protect the internal conductor and insulation layer from the external environment, such as humidity, temperature, etc. The cotton paper layer and the non-woven fabric layer also help to dissipate the heat generated inside the cable, maintain the stable operation of the cable, and improve the performance and reliability of the product.

[0054] Furthermore, the protective layer also includes an outer coating layer 109 coated on the outside of the wrapping layer 108 for insulating and protecting the internal cable core.

[0055] In this embodiment, the outer coating 109 is the outermost protective layer of the cable, which is usually made of plastic, rubber or other materials. Its main function is to protect the internal conductor and insulation layer from the external environment, such as humidity, temperature, mechanical damage, etc. The outer coating 109 has a certain wear resistance to protect the internal structure of the cable from mechanical damage. The outer coating 109 has anti-aging properties, can resist the erosion of environmental factors such as ultraviolet rays and oxidation, and maintain its stable performance. The outer coating 109 has good corrosion resistance and can resist the erosion of chemical substances such as acids and alkalis. The outer coating 109 also has a certain waterproof performance, which can prevent moisture from penetrating into the cable and affecting its performance, thereby ensuring the safety and reliability of the product.

[0056] Furthermore, the outer layer 109 is a polyvinyl chloride layer, a thermoplastic elastomer layer or a polyurethane layer.

[0057] In this embodiment, the outer layer 109 may be made of a polyvinyl chloride (PVC, PolyvinylChloride) layer, a thermoplastic elastomer (TPE, Thermoplastic Elastomer) layer or a polyurethane (PTU) layer, which mainly plays a protective role to prevent leakage and protect the internal core wire from being damaged.

[0058] Furthermore, the high-toughness cable is a cylindrical cable, and its two ends are straight and its middle is a spiral ring.

[0059] In this embodiment, the high-toughness cable has high toughness and can be extended when stretched under force and can be contracted without force. The middle spiral ring corresponds to the retractable length of the elastic steel cable, and the diameter of the spiral wire of the middle spiral ring can be customized according to requirements. The elastic steel cable is in a spiral ring shape to ensure the long-term retractability of the high-toughness cable. The two ends of the high-toughness cable are straight, which is convenient for connecting the charging gun and charging cabinet of the electric vehicle charging pile.

[0060] The high-toughness cable provided in this embodiment includes a cable core and a protective layer coated on the outside of the cable core. The cable core includes a current line, a signal transmission line 102 and an elastic steel cable. The current line, the signal transmission line 102 and the elastic steel cable are tightly twisted into the cable core. The elastic steel cable has the characteristics of high toughness, strong recovery and long life. Compared with conventional spring cables, the production process of the high-toughness cable is to heat and cool the insulating plastic coated on the outer layer 109 of the cable. The processing technology is: heating the plastic particles to a high temperature to form a viscous state, and coating them on the outer layer 109 through equipment. It is a one-time processing process and no longer needs to be heated and curled twice to achieve a spring-like expansion and contraction effect. The expansion and contraction effect of the high-toughness cable is formed by the elastic steel cable. After multiple stretching and bending, the elastic steel cable can still have very good elasticity and toughness, and will not lose elasticity due to long-term use. It can well cope with the occasions of repeated bending and stretching during the use of electric vehicle charging piles, and has high safety and reliability.

[0061] It should be noted that the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in the field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0062] The above description is only a partial or preferred embodiment of the present invention. Neither the text nor the drawings can limit the scope of protection of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the overall concept of the present invention, or direct / indirect application in other related technical fields are included in the scope of protection of the present invention.

Claims

1. A high-toughness cable, used in electric vehicle charging piles, characterized in that: It comprises a cable core and a protective layer covering the outside of the cable core, wherein the cable core comprises a current line, a signal transmission line and an elastic steel cable, and the current line, the signal transmission line and the elastic steel cable are tightly twisted to form the cable core; Wherein, the elastic steel cable comprises a first elastic steel cable, a second elastic steel cable and a third elastic steel cable, and the first elastic steel cable, the second elastic steel cable, the third elastic steel cable, the current line and the signal transmission line are tightly twisted into the cable core; Wherein, the two ends of the high-toughness cable are in a straight line shape, and the middle part is in a spiral ring shape.

2. The high-tenacity cable according to claim 1, characterized in that: The retractable length range of the elastic steel cable is 85%-95% of the overall length of the elastic steel cable.

3. The high-tenacity cable according to claim 1, characterized in that: The current line comprises a ground line, a phase line and a neutral line capable of passing a voltage of at least 500V, and the ground line, the phase line and the neutral line are all covered with an insulating layer.

4. The high-tenacity cable according to claim 3, characterized in that: The phase line is an AC power phase line, and the signal transmission line is a pure copper conductor.

5. The high-tenacity cable according to claim 1, characterized in that: The protective layer includes a wrapping layer for supporting the cable core.

6. The high-tenacity cable according to claim 5, characterized in that: The wrapping layer is a cotton paper layer or a non-woven fabric layer.

7. The high-tenacity cable according to claim 5, characterized in that: The protective layer also includes an outer coating layer which is coated outside the wrapping layer and is used for insulating and protecting the inner cable core.

8. The high-tenacity cable according to claim 7, characterized in that: The outer layer is a polyvinyl chloride layer, a thermoplastic elastomer layer or a polyurethane layer.

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