Integrated cable for 200A direct current charging gun

Abstract

An integrated cable for a 200A direct current charging gun is characterized in that four circles of wires are coaxially and tightly arranged in an insulating jacket of the integrated cable, and the number of the four circles of wires is 12, 21, 15 and 4 in sequence from outside to inside; in terms of functions, the 12 wires in the first circle, the 21 wires in the second circle and one wire in the third circle are charging wires; the eight wires in the third circle are signal wires; the rest six leads in the third circle and the two leads in the fourth circle are auxiliary power lines; and the remaining two wires in the fourth circle are shielding wires. According to the integrated cable, on the premise that the charging power is guaranteed, the 12 wires of the first circle, the 21 wires of the second circle and one wire of the third circle serve as charging wires, the wire diameter of the integrated cable is reduced to 23 mm from 36-38 mm, the bending radius is reduced to 80 mm from 180 mm, the use experience feeling of a user is improved, and charging operation becomes easy. Under the same bearing, the cross-sectional area of the wire of the integrated cable is only 48 square millimeters, so that copper materials are greatly saved.

Description

Technical Field

[0001] The utility model relates to the field of new energy electric vehicles, and in particular to an integrated cable for a 200A DC charging gun. The integrated cable is applicable to the GB20234.3-2015 DC charging gun standard, the HPC super charging gun standard, the IEC 62196-3 American charging gun standard, the IEC 62196-3 European charging gun standard and the IEC 62196-3 Japanese charging gun standard. Background Art

[0002] There are two main factors that restrict the development of new energy electric vehicles: one is the short battery life; the other is the long charging time. To achieve fast charging, the charging current must be increased, which requires the integrated cable to have a large current carrying capacity. At present, the natural heat dissipation DC charging guns used in China are 250A and 200A, while the natural heat dissipation DC charging guns of foreign European, American and Japanese standards are 200A. Although charging guns at home and abroad are not universal, the integrated cables connected to the charging guns have roughly the same structure, with only differences in the number of signal lines.

[0003] like Figure 1 As shown in the figure, the existing 200A DC charging integrated cable commonly used at home and abroad has two charging wires, DC+ and DC-, arranged side by side inside the insulating outer sheath. PE ground wires and several signal wires and functional wires are distributed above and below the two charging wires, and the rest of the space is filled. It has the following defects:

[0004] Defect 1: The wire diameter is too thick. The outer diameter of the existing 200A DC charging integrated cable is usually 36-38mm, the wire diameter is relatively thick and difficult to bend.

[0005] Defect 2: The layout of the wires is unreasonable. The PE ground wire and several signal wires and functional wires are respectively arranged above and below the two charging wires. This asymmetric layout structure has two problems. First, the gap is too large, and fillers need to be added to fill the gap. After filling, the integrated cable is hard, has poor roundness, and is not beautiful. Second, the two charging wires are arranged side by side, which makes the integrated cable difficult to bend in one direction, but easier to bend in the other direction, making the integrated cable anisotropic in the bending direction.

[0006] Defect 3: Poor user experience. The length of the existing standard integrated cable is usually 5 meters, and each meter weighs about 3 kilograms. The weight of the DC charging gun is about 1.5 kilograms. The sum of the two equals 16.5 kilograms, which is very difficult for charging operations. Utility Model Content

[0007] In order to overcome the shortcomings of the background technology, the following technical solutions are adopted:

[0008] An integrated cable for a 200A DC charging gun, with four circles of wires coaxially and closely arranged inside the insulated outer sheath of the integrated cable, the number of wires in the four circles being 12, 21, 15 and 4 from the outside to the inside; functionally, the 12 wires in the first circle, the 21 wires in the second circle and the 1 wire in the third circle are charging wires; the 8 wires in the third circle are signal lines; the remaining 6 wires in the third circle and the 2 wires in the fourth circle are auxiliary power lines; the remaining 2 wires in the fourth circle are shielding wires.

[0009] To further improve the technical solution, the wire diameter of the second circle of wire is the same as the wire diameter of the third circle of wire.

[0010] To further improve the technical solution, the 12 charging cables in the first circle are divided into two groups, namely 6 DC+ charging cables and 6 DC- charging cables.

[0011] To further improve the technical solution, the 21 charging cables in the second circle and the 1 charging cable in the third circle are evenly bundled into two cable harnesses when in use, and the two cable harnesses are respectively a DC+ charging cable and a DC- charging cable.

[0012] To further improve the technical solution, the eight signal lines in the third circle are T1+ line, T1- line, T2+ line, T2- line, PIN1 line, PIN2 line, EL+ line and EL- line.

[0013] To further improve the technical solution, the remaining 6 auxiliary power lines in the third circle and the 2 auxiliary power lines in the fourth circle are evenly bundled into two wire harnesses when in use, and the two wire harnesses are A+ auxiliary power line and A- auxiliary power line respectively.

[0014] To further improve the technical solution, the shielded wires are double-parallel shielded wires, one of which is CC1 wire and CC2 wire, and the other is S+ wire and S- wire.

[0015] To further improve the technical solution, an insulating sleeve is wrapped around the outside of the charging cable, the signal cable and the auxiliary power cable, and the material of the insulating sleeve is TPE, F46, or polyimide.

[0016] To further improve the technical solution, a wrapping tape is provided between each coil of the conducting wire, and the wrapping tape is formed by winding a non-woven tape or a metal foil tape.

[0017] To further improve the technical solution, the gaps between the 12 charging cables in the first circle are filled with fillers, and the material of the fillers is PP, or thin glass fiber rope, or heat-absorbing and heat-conductive material.

[0018] Due to the adoption of the above technical solution, compared with the background technology, the integrated cable has the following beneficial effects:

[0019] 1. In order to minimize the wire diameter of the integrated cable, this integrated cable uses 12 wires in the first circle, 21 wires in the second circle, and 1 wire in the third circle as charging cables while ensuring the charging power, so that the wire diameter of the integrated cable is reduced from 36-38 mm to 23 mm, and the bending radius is reduced from 180 mm to 80 mm, which improves the user experience and makes the charging operation easier.

[0020] 2. Under the same load, the cross-sectional area of ​​the copper conductor of the traditional 200A DC charging cable is 60 square millimeters, while the cross-sectional area of ​​the copper conductor of this integrated cable is only 48 square millimeters, which greatly saves copper materials.

[0021] 3. The layout of the integrated cable is reasonable, which eliminates the anisotropy of the integrated cable in the bending direction. When pulled, each charging cable can evenly disperse the tension, thereby improving the tensile performance of the integrated cable.

[0022] 4. This integrated cable has good heat dissipation effect and low temperature rise. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Shown is a schematic diagram of existing domestic and foreign general integrated cables.

[0024] Figure 2 Shown is a cross-sectional schematic diagram of the integrated cable.

[0025] In the figure: 1. The first circle of wire; 2. The second circle of wire; 3. The third circle of wire; 4. The double-parallel shielded wire; 5. The fourth circle of wire; 6. Tape A; 7. Copper wire mesh; 8. Tape B; 9. Tape C; 10. Tape D; 11. Tape E; 12. Insulation jacket; 13. Filler. DETAILED DESCRIPTION

[0026] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention. It should be noted that in the description of the present invention, the terms "front", "rear", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, which are only for the convenience of description, rather than indicating or implying that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. It should also be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or the internal connection of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0027] An integrated cable for a 200A DC charging gun, such as Figure 2 As shown, four turns of wires are coaxially and closely arranged inside the insulating outer sheath 12 of the integrated cable, and the number of the four turns of wires is 12, 21, 15 and 4 from the outside to the inside. Due to the coaxial design, the anisotropy of the integrated cable in the bending direction is eliminated. When pulled, each charging line can evenly disperse the tension, thereby improving the tensile performance of the integrated cable.

[0028] In terms of wire diameter, the first circle wire 1 is the thickest, the second circle wire 2 and the third circle wire 3 have the same wire diameter, and the two single wires in the fourth circle wire 5 are the thinnest. After the wire diameter of each circle wire is reasonably designed, each circle wire can be closely arranged along the circumferential direction, improving the utilization rate of the space inside the insulating outer sheath 12.

[0029] From a functional perspective, the 12 wires in the first circle, the 21 wires in the second circle and the 1 wire in the third circle are charging wires; the 8 wires in the third circle are signal lines; the remaining 6 wires in the third circle and the 2 wires in the fourth circle are auxiliary power lines; and the remaining 2 wires in the fourth circle are shielding wires.

[0030] The 12 thickest charging cables in the first circle are divided into two groups, namely 6 DC+ charging cables and 6 DC- charging cables. In order to minimize the wire diameter of the integrated cable while ensuring the charging power, the 21 thinner charging cables in the second circle and the 1 thinner charging cable in the third circle are bundled into two thicker wire bundles (each bundle has 11 thinner charging cables) during use. These two thicker wire bundles are the DC+ charging cable and the DC- charging cable. After bundling, the conductivity of each wire bundle is 1.2 times that of a single charging cable in the first circle. In this way, the integrated cable actually has 7 thick DC+ charging cables and 7 thick DC- charging cables. Obviously, using the second circle wire 2 and part of the wires in the third circle as additional charging cables can make reasonable use of space and minimize the wire diameter. In addition, under the same load, multiple small-diameter charging cables can replace a single large-diameter charging cable. This can save copper and facilitate heat dissipation, reducing temperature rise.

[0031] The eight signal lines in the third circle are T1+ line, T1- line, T2+ line, T2- line, PIN1 line, PIN2 line, EL+ line and EL- line. These signal lines are the communication control lines required between the charging pile and the electric vehicle.

[0032] The current carrying capacity of the auxiliary power line is second only to the DC+ charging line and the DC- charging line. In order to minimize the wire diameter, the remaining 6 auxiliary power lines in the third circle and the 2 auxiliary power lines in the fourth circle are evenly bundled into two thicker wire harnesses when in use. The two thicker wire harnesses are the A+ auxiliary power line and the A- auxiliary power line.

[0033] In this embodiment, both shielded wires are double parallel shielded wires 4, one of which is CC1 wire and CC2 wire, and the other is S+ wire and S- wire. The shielded wire is wrapped with a metal shielding sleeve to prevent interference from external electromagnetic noise.

[0034] In order to ensure the insulation of each functional line, an insulating sleeve is wrapped around the outside of the charging line, signal line and auxiliary power line. The material of the insulating sleeve can be any one of TPE material, F46 material and polyimide material.

[0035] In order to protect each circle of wires and improve the tensile strength of the integrated cable, a wrapping tape is provided between each circle of wires, and the wrapping tape is wound by a non-woven tape or a metal foil tape. In this embodiment, a wrapping tape E11 is wound between the insulating outer sheath 12 and the first circle of wires 1, a wrapping tape D10 is wound between the first circle of wires 1 and the second circle of wires 2, a wrapping tape C9 is wound between the second circle of wires 2 and the third circle of wires 3, and three layers of windings are wound between the third circle of wires 3 and the fourth circle of wires 5, namely, a wrapping tape B8, a copper wire mesh 7, and a wrapping tape A6.

[0036] Since the pores between the first circle of wires 1 are the largest, the gaps between the 12 charging wires in the first circle are filled with fillers 13. According to design requirements, the material of the filler 13 can be PP, thin glass fiber rope, or heat-absorbing and heat-conductive material, such as paraffin. PP and thin glass fiber rope can increase the tensile strength of the integrated cable, and heat-absorbing and heat-conductive material can reduce the temperature of the charging cable.

[0037] It should be noted that this integrated cable is applicable to the GB20234.3-2015 DC charging gun standard, the HPC super charging gun standard, the IEC 62196-3 American charging gun standard, the IEC 62196-3 European charging gun standard, and the IEC 62196-3 Japanese charging gun standard.

[0038] Although the embodiments of the present invention have been shown and described, it is understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the protection scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. An integrated cable for a 200A DC charging gun, characterized by: There are four circles of wires coaxially and closely arranged inside the insulated outer sheath of the integrated cable. The number of wires in the four circles are 12, 21, 15 and 4 from the outside to the inside. From a functional perspective, the 12 wires in the first circle, the 21 wires in the second circle and the 1 wire in the third circle are charging cables; the 8 wires in the third circle are signal lines; the remaining 6 wires in the third circle and the 2 wires in the fourth circle are auxiliary power lines; the remaining 2 wires in the fourth circle are shielding wires.

2. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The wire diameter of the second circle of wire is the same as the wire diameter of the third circle of wire.

3. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The 12 charging cables in the first circle are divided into two groups, namely 6 DC+ charging cables and 6 DC- charging cables.

4. The integrated cable for a 200A DC charging gun according to claim 3, characterized in that: The 21 charging cables in the second circle and the 1 charging cable in the third circle are evenly bundled into two cable harnesses when in use, and the two cable harnesses are respectively a DC+ charging cable and a DC- charging cable.

5. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The eight signal lines in the third circle are T1+ line, T1- line, T2+ line, T2- line, PIN1 line, PIN2 line, EL+ line and EL- line.

6. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The remaining 6 auxiliary power lines in the third circle and the 2 auxiliary power lines in the fourth circle are evenly bundled into two wire harnesses when in use. The two wire harnesses are respectively A+ auxiliary power line and A- auxiliary power line.

7. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The shielded wires are double parallel shielded wires, one of which is a CC1 wire and a CC2 wire, and the other double parallel shielded wire is an S+ wire and an S- wire.

8. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The charging cable, signal cable and auxiliary power cable are wrapped with an insulating sleeve, and the material of the insulating sleeve is TPE, F46 or polyimide.

9. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: A wrapping tape is arranged between each circle of the conducting wire, and the wrapping tape is formed by winding a non-woven fabric tape or a metal foil tape.

10. The integrated cable for a 200A DC charging gun according to claim 1, characterized in that: The gaps between the 12 charging cables in the first circle are filled with fillers made of PP, thin glass fiber rope, or heat-absorbing and heat-conductive material.

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