A flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles

Abstract

The utility model discloses a flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles, which belongs to the field of cable technology. The center of the cable is a cooling tube, and the outside of the cooling tube is a conductor. The conductor adopts a tile-shaped tightly compressed twisted structure and is insulated in phases. The cooling tube, the conductor and the insulation layer are twisted into a cable core, which is wrapped by a braided layer. A layer of aluminum-plastic composite tape is wrapped around the braided layer, and the outside of the aluminum-plastic composite tape is a sheath layer. When the utility model is bent, the cooling tube can be freely extended and retracted, and the liquid flow is not restricted, which will not cause a sharp rise in local temperature and affect the current carrying capacity. The conductor can realize multi-line functions at the same time, and the terminal crimping is not restricted. The conductor in the cable core is insulated in phases and the cable core is twisted, which improves the bending performance and reduces the radial pressure on the central cooling pipe and the conductor during bending. The overall structure of the utility model solves the problems of performance degradation and limited space in the vehicle caused by bending.

Description

Technical Field

[0001] The utility model belongs to the technical field of cables, and in particular relates to a liquid-cooled high-voltage cable for new energy vehicles. Background Art

[0002] With the rapid development and popularization of electric vehicles, charging technology is also constantly improving. Liquid-cooled high-voltage cables, as an innovative technology to increase current carrying capacity, have many advantages and applicability in the field of new energy vehicles. The principle of liquid cooling technology is to add a liquid cooling tube inside the cable. Through a sealed cycle, the cooling system and the charging system coexist and work together, so that the cable can still maintain a low constant temperature during high-power charging, and can fully charge the car battery in a short time, or quickly replenish the power.

[0003] The cooling tubes of existing liquid-cooled high-power cables for new energy vehicles are almost all smooth tubes, such as Figure 1 As shown, bending may occur during use, which will hinder the flow of coolant and affect the stability of the cooling liquid flow, thereby affecting the cooling effect on the conductor, resulting in the cable not being cooled in time, the working temperature level being limited, and easily causing the local temperature at the bending position to rise sharply, shortening the service life of the cable, and causing breakdown safety problems. It is also easy for the cooling tube to be separated from the connector, the cooling tube to rupture, etc., resulting in cooling liquid leakage; the transmission conductor is a tubular structure, and a single cable can only achieve a single current transmission. At the same time, the tubular conductor is extremely difficult to control during the terminal crimping process; the control wire core may break during mobile use; the existing liquid-cooled high-power cable for new energy vehicles is generally integrally insulated, and radial pressure is exerted on the conductor and the cooling tube during the bending process, which is easy to cause the cooling tube to wrinkle and deform. All of these will affect the charging safety of new energy vehicles. At the same time, the smooth tube structure of the cooling tube and the overall insulation of the cable conductor also limit the bending radius of the cable when it is laid in the car, resulting in space waste. Utility Model Content

[0004] The technical problem to be solved by the utility model is to provide a liquid-cooled high-voltage cable for new energy vehicles, which has good bending properties, does not affect the flow of cooling liquid, solves the problem of single transmission of electric energy by tubular conductors, decomposes the radial pressure on the cooling tube and the conductor when the cable is bent, solves the problem of limited cable bending radius, saves laying space in the vehicle and reduces the difficulty of wiring harness design and use.

[0005] In order to solve the above technical problems, the technical solution adopted by the utility model is: a flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles, including a cooling tube, a conductor, an insulating layer, a braided layer, an aluminum-plastic composite tape, and a sheath layer; the cooling tube is located in the center of the cable, the outside of the cooling tube is the conductor, and the outside of the conductor is in close contact with the insulating layer; the cooling tube, the conductor, and the insulating layer are twisted together to form a cable core, and a braided layer is extruded on the outside of the cable core; a layer of aluminum-plastic composite tape is wrapped around the outside of the braided layer; and a sheath layer is extruded on the outside of the aluminum-plastic composite tape.

[0006] The further improved scheme in the above technical scheme is as follows:

[0007] 1. The cooling pipe is a polyurethane annular corrugated pipe.

[0008] 2. The conductor is three-core or four-core, with a tile-shaped tightly twisted structure.

[0009] 3. The diameter of the single filament of the braided silk is 0.12-0.21mm, and the braiding density is ≥85%. The braiding density is the percentage of the surface area covered by the braided material to the total surface area of ​​the braided layer.

[0010] 4. The wrapping overlap rate of the aluminum-plastic composite tape is ≥25%. The wrapping overlap rate refers to the ratio of the width of the overlap or gap in the overlapping wrapping along the width of the tape to the width of the tape.

[0011] 5. The concentricity of the sheath layer is ≥ 70%. The concentricity of the sheath refers to the degree of the circular cross-section formed by the sheath during the manufacturing process.

[0012] Through the above design scheme, the present invention can bring the following beneficial effects:

[0013] 1. The cooling pipe is a telescopic bellows. When bent, the cooling pipe can expand and contract freely, and the flow of coolant is not restricted, which will not cause a sharp rise in local temperature and the current carrying capacity will not be reduced.

[0014] 2. The conductor adopts a split tile-shaped structure, the conductor can realize multi-line functions at the same time, and the terminal crimping is not restricted.

[0015] 3. The insulated cable core part adopts tile-shaped phase-separated insulation and is twisted. The insulation of each phase maintains independent freedom and relative slippage, which improves the bending performance and reduces the radial pressure on the central cooling pipe and conductor during bending.

[0016] 4. The overall structure of the cable solves the problems of performance degradation caused by bending and limited laying space in the car. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of a cooling pipe with a smooth structure in the background technology.

[0018] Figure 2This is a schematic structural diagram of a liquid-cooled high-voltage cable cooling tube with an easily bendable tile-shaped cross-section for new energy vehicles according to the utility model.

[0019] Figure 3 This is a schematic diagram of a tile-shaped cross-section of an easily bendable tile-shaped cross-section liquid-cooled high-voltage cable conductor for new energy vehicles according to the utility model.

[0020] Figure 4 This is a cross-sectional view of a liquid-cooled high-voltage cable with an easily bendable tile-shaped cross-section for new energy vehicles according to the utility model.

[0021] In the figure, 1 is cooling tube, 2 is conductor, 3 is insulation layer, 4 is braided layer, 5 is aluminum-plastic composite tape, and 6 is sheath layer. DETAILED DESCRIPTION

[0022] The present invention is further described below with reference to the accompanying drawings and specific embodiments:

[0023] Example 1

[0024] 1. As Figure 4 The center of the cable is a cooling tube 1, which is made of polyurethane and has a ring-shaped telescopic structure. The diameter of the corrugated cooling tube 1 is 4 mm, and the tube is hollow. Figure 2 shown.

[0025] 2. The outside of the cooling tube 1 is the conductor 2, which is a three-core conductor. The material of the conductor 2 is annealed bare copper monofilament, the purity is required to be above 99.99%, the number of strands is 25, the monofilament diameter is 0.21mm, and the resistivity is ≤0.017241Ω·mm 2 / m; conductor 2 is insulated in phases, and the outer side is in close contact with the insulating layer 3. The insulating layer 3 is made of 200℃ grade silicone rubber, with the thinnest point of 1.00mm and the maximum width of the fan after extrusion is 5.4mm; conductor 2 adopts a tile-shaped compact twisted structure, and the nominal cross-sectional area of ​​conductor 2 is 8mm 2 , the resistance of conductor 2 is ≤2.32Ω / m, conductor 2 is pressed tightly, the filling factor of conductor 2 is ≥90%, the arc radius R2 of the tile-shaped stranded wire core of conductor 2 close to the cable center and the tile-shaped cross-sectional area S of conductor 2 are referenced Figure 3 And the following formula determines:

[0026] R2=R3+δ

[0027]

[0028] Wherein: R1 is the radius of the arc of the core of the conductor 2 with the cable center as the center and away from the cable center, R3 is the outer radius of the cooling tube 1, δ is the thickness of the insulating layer 3 in contact with the cooling tube 1 with the cable center as the center, φ is the circumferential angle of the core arc of the conductor 2 with the unit of "°", and the units of other parameters are mm.

[0029] 3. The cooling tube 1, the conductor 2 and the insulating layer 3 are twisted together to form a cable core. The cage twisting process is adopted during twisting. The pitch is 500mm. After twisting, the outer diameter of the cable core is 18.1mm.

[0030] 4. A braided layer 4 is extruded on the outside of the cable core. The braided layer 4 is woven with tinned copper wire. The diameter of the single wire of the braided wire is 0.21mm. A 24-spindle horizontal braiding equipment is used, and the braiding density is ≥85%.

[0031] 5. A layer of aluminum-plastic composite tape (AL-PET) 5 is wrapped around the braided layer 4, with an overlap rate of ≥25%. The aluminum-plastic composite tape (AL-PET) 5 has a nominal thickness of 0.03 mm and together with the braided layer 4 forms a shielding layer.

[0032] 6. A sheath layer 6 is extruded on the outside of the aluminum-plastic composite tape (AL-PET) 5, and is made of cross-linked polyethylene (XLPE) or silicone rubber material. It adopts a cold extrusion process and a multi-pass hot vulcanization process to ensure that the sheath is round and easy to peel. The concentricity is ≥70%, the sheath layer thickness is ≥0.8mm, and the sheath ovality is ≤8%. The sheath ovality indicates whether the cross-section of the wire is round. The sheath ovality = (maximum outer diameter - minimum outer diameter) / nominal outer diameter, and then converted into a percentage. The sheath outer diameter is: 21.00mm.

[0033] Example 2

[0034] 1. As Figure 4 The center of the cable is a cooling tube 1, which is made of polyurethane and has a ring-shaped telescopic structure. The diameter of the corrugated cooling tube 1 is 4 mm, and the tube is hollow. Figure 2 shown.

[0035] 2. The outside of the cooling tube 1 is the conductor 2, which has four cores. The material of the conductor 2 is annealed bare copper monofilament, the purity is required to be above 99.99%, the number of strands is 500, the monofilament diameter is 0.41mm, and the resistivity is ≤0.017241Ω·mm 2 / m; conductor 2 is insulated in phases, and the outer side is in close contact with the insulating layer 3. The insulating layer 3 is made of 200℃ grade silicone rubber, with the thinnest point of 1.00mm and the maximum width of the fan after extrusion is 5.4mm; conductor 2 adopts a tile-shaped compact twisted structure, and the nominal cross-sectional area of ​​conductor 2 is 8mm 2 , the resistance of conductor 2 is ≤2.32Ω / m, conductor 2 is pressed tightly, the filling factor of conductor 2 is ≥90%, the arc radius R2 of the tile-shaped stranded wire core of conductor 2 close to the cable center and the tile-shaped cross-sectional area S of conductor 2 are referenced Figure 3 And the following formula determines:

[0036] R2=R3+δ

[0037]

[0038] Among them, R1 is the radius of the tile-shaped stranded wire core arc of conductor 2 with the cable center as the center and away from the cable center, R3 is the outer radius of the cooling tube 1, δ is the thickness of the insulating layer 3 in contact with the cooling tube 1 with the cable center as the center, φ is the circumferential angle of the tile-shaped stranded wire core arc of conductor 2, the unit is "°", and the units of other parameters are mm.

[0039] 3. The cooling tube 1, the conductor 2 and the insulating layer 3 are twisted together to form a cable core. The cage twisting process is adopted during twisting. The pitch is 1000mm. After twisting, the outer diameter of the cable core is 18.5mm.

[0040] 4. A braided layer 4 is extruded on the outside of the cable core. The braided layer 4 is woven with tinned copper wire. The diameter of the single wire of the braided wire is 0.12mm. A 16-spindle horizontal braiding equipment is used, and the braiding density is ≥85%.

[0041] 5. A layer of aluminum-plastic composite tape (AL-PET) 5 is wrapped around the braided layer 4, with an overlap rate of ≥25%. The aluminum-plastic composite tape (AL-PET) 5 has a nominal thickness of 0.03 mm and together with the braided layer 4 forms a shielding layer.

[0042] 6. A sheath layer 6 is extruded on the outside of the aluminum-plastic composite tape (AL-PET) 5, which is made of cross-linked polyethylene (XLPE) or silicone rubber material, and adopts a cold extrusion process and a multi-pass hot vulcanization process to ensure that the sheath is round and easy to peel off, with a concentricity of ≥70%, a sheath layer thickness of ≥0.8mm, a sheath ovality of ≤8%, and a sheath outer diameter of 21.50mm.

[0043] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles, characterized in that: It includes a cooling tube, a conductor, an insulating layer, a braided layer, an aluminum-plastic composite tape, and a sheath layer; the cooling tube is located in the center of the cable; the outside of the cooling tube is the conductor, and the outside of the conductor is in close contact with the insulating layer; the cooling tube, the conductor, and the insulating layer are twisted together to form a cable core, and a braided layer is extruded on the outside of the cable core; a layer of aluminum-plastic composite tape is wrapped around the outside of the braided layer; and a sheath layer is extruded on the outside of the aluminum-plastic composite tape.

2. The flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles according to claim 1, characterized in that: The cooling pipe is a polyurethane annular corrugated pipe.

3. The flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles according to claim 1, characterized in that: The conductor is three-core or four-core and adopts a tile-shaped tightly compressed stranded structure.

4. The flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles according to claim 1, characterized in that: The diameter of the single filament of the braided silk is 0.12-0.21 mm, and the braiding density is ≥85%.

5. The flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles according to claim 1, characterized in that: The wrapping overlap rate of the aluminum-plastic composite tape is ≥25%.

6. The flexible tile-shaped cross-section liquid-cooled high-voltage cable for new energy vehicles according to claim 1, characterized in that: The concentricity of the sheath layer is ≥70%.

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