Charging cable and charging system for electric vehicle

Abstract

The utility model provides a charging cable and a charging system for an electric vehicle. The charging cable includes: a plurality of power conductors; and a plurality of tubes, each of the plurality of tubes surrounding a corresponding one of the power conductors, a cooling medium passage being formed between an outer circumferential surface of the power conductor and an inner circumferential surface of the tube, through which a cooling medium flows. Each of the plurality of tubes includes an offset portion, a distance in a radial direction of the tube between an inner circumferential surface of the offset portion and a central axis of a corresponding power conductor varies along a length direction of the tube in a longitudinal cross-sectional view of the tube. The charging cable provided by the utility model has good flexibility and bending degree, so that bending and distortion possibly encountered in the use process of the cable can be easily dealt with.

Description

Technical Field

[0001] The present application relates to the field of new energy, and particularly to a charging cable (also known as a liquid-cooled cable) and a charging system for new energy devices. Background Art

[0002] A liquid-cooled cable is a special type of cable for new energy devices. Its main feature is to use a liquid liquid-cooling system to reduce the operating temperature of the device and improve the performance and efficiency of the device. This type of cable is usually used for devices under special working conditions such as high power density, high frequency, and high temperature, such as power electronic devices, power converters, electric vehicles, solar inverters, etc.

[0003] In the charging equipment of electric vehicles, the liquid-cooled cable usually needs to be installed outside the vehicle. The charging gun is connected to the vehicle's charging interface via the liquid-cooled cable, and the cable undergoes various different bends and twists during the charging operation. At the same time, stress concentration may occur during the bending process of the liquid-cooled cable. Stress concentration may cause structural damage inside the cable, thereby affecting its service life and performance.

[0004] The liquid-cooled tubes of the liquid-cooled cables in the related art are not easily bendable, which is inconvenient for charging operations. The bending radius of some liquid-cooled tubes is small. If the liquid-cooled tube is bent to a radius lower than the allowable minimum bending radius during the operation, the liquid-cooled tube may not be able to recover, causing the cooling medium flow channel to deform, thus affecting normal charging. In addition, the liquid-cooled tube is not resistant to high temperatures and is prone to softening at high temperatures.

[0005] Therefore, there is a need for a charging cable, a charging gun, and a charging system that are easily bendable, have high flexibility and high adaptability, and are resistant to high temperatures. Summary of the Utility Model

[0006] This section provides a general overview of the present application, rather than a full disclosure of the entire scope or all features of the present application.

[0007] In view of the problems existing in the above conventional technologies, there is a need to improve the related charging cable to overcome or alleviate all or at least part of the above technical problems.

[0008] In some exemplary embodiments, the present application provides a charging cable, which may include: a plurality of power conductors, each of the plurality of power conductors extending between a first end portion and a second end portion opposite to the first end portion of the charging cable; and a plurality of tubes, each of the plurality of tubes surrounding a corresponding one of the power conductors, and a cooling medium channel for the cooling medium to flow is formed between the outer peripheral surface of the power conductor and the inner peripheral surface of the tube.

[0009] Each of the plurality of tubes may include a biasing portion, and in a longitudinal cross-sectional view of the tube, the distance in the radial direction of the tube between the inner circumferential surface of the biasing portion and the central axis of the corresponding power conductor varies along the length of the tube. This structure of the charging cable of the present application enables the charging cable to have good flexibility and bendability, so as to be able to easily cope with the bending and twisting that the cable may encounter during use.

[0010] In some exemplary embodiments, the biasing portion may include at least one of a helical portion and a corrugated portion.

[0011] In some exemplary embodiments, the corrugated portion may include a plurality of corrugated convex portions arranged at intervals from each other, and each corrugated convex portion extends along the circumferential direction of the tube.

[0012] In some exemplary embodiments, in a longitudinal cross-sectional view of the tube, each corrugated convex portion has a V-shaped, U-shaped or trapezoidal shape.

[0013] In some exemplary embodiments, the helical portion may include a helical convex portion that extends in a helical manner around the central axis of the tube.

[0014] In some exemplary embodiments, the biasing portion may include a plurality of corrugated portions and / or a plurality of helical portions.

[0015] In some exemplary embodiments, the length of the biasing portion may be 1% to 100% of the length of the tube. Optionally, the length of the biasing portion is 20% to 80% of the length of the tube.

[0016] In some exemplary embodiments, the minimum bending radius of the biasing portion is in the range of 4 to 10 times the outer diameter of the tube, and the minimum bending radius of the charging cable is in the range of 4 to 10 times the outer diameter of the charging cable.

[0017] In some exemplary embodiments, the plurality of tubes are formed as liquid outlet tubes, and the charging cable may further include a plurality of liquid inlet tubes that are parallel and fluidly connected to the liquid outlet tubes, and a cooling medium flows into the liquid inlet tubes and flows out through the liquid outlet tubes.

[0018] In some exemplary embodiments, the plurality of power conductors include a positive power conductor and a negative power conductor, the liquid inlet tubes include a positive liquid inlet tube and a negative liquid inlet tube; the liquid outlet tubes include a positive liquid outlet tube that is parallel and fluidly connected to the positive liquid inlet tube, and a negative liquid outlet tube that is parallel and fluidly connected to the negative liquid inlet tube, the positive power conductor is disposed in the positive liquid outlet tube, and the negative power conductor is disposed in the negative liquid outlet tube.

[0019] In some exemplary embodiments, the plurality of power conductors may include two positive power conductors and two negative power conductors. The inlet pipe may include a positive inlet pipe and a negative inlet pipe; the outlet pipe includes two positive outlet pipes that are parallel to and in fluid communication with the positive inlet pipe and two negative outlet pipes that are parallel to and in fluid communication with the negative inlet pipe, and the two positive power conductors are respectively disposed in the two positive outlet pipes, and the two negative power conductors are respectively disposed in the two negative outlet pipes.

[0020] In some exemplary embodiments, when a DC current of 500 A to 800 A is applied to the power conductor, the temperature of the power conductor of the charging cable is in the range of 50 degrees to 85 degrees.

[0021] In some exemplary embodiments, the nominal cross-sectional area of the wire core of each power conductor among the plurality of power conductors is in the range of 16 mm 2 to 240 mm 2 range.

[0022] In some exemplary embodiments, the charging cable may further include a ground wire, and the nominal cross-sectional area of the wire core of the ground wire is in the range of 2 mm 2 to 100 mm 2 range.

[0023] In some exemplary embodiments, the charging cable may further include a plurality of signal lines, and the nominal cross-sectional area of the wire core of each signal line among the signal lines is in the range of 0.2 mm 2 to 2.5 mm 2 range.

[0024] In some exemplary embodiments, the pipe is made of fluoroplastics.

[0025] In some exemplary embodiments, the present application provides a charging system for an electric vehicle. The charging system may include: a charging gun; and a charging cable that connects the charging gun to a cooling unit, a first end of the charging cable is connected to the charging gun, and a second end of the charging cable opposite to the first end is connected to the cooling unit.

[0026] The charging cable may include a plurality of pipes configured for the flow of a cooling medium, each of the plurality of pipes includes a deformable portion capable of bending, in a longitudinal sectional view of the pipe, the deformable portion includes a plurality of protrusions protruding along the radial direction of the pipe, there is a gap between adjacent protrusions, and the plurality of protrusions are configured such that: when the charging cable is bent, the gap changes under the action of a bending force to accommodate the relative movement between adjacent protrusions.

[0027] The charging system provided according to the exemplary embodiments of the present application has a charging cable with a deformable portion, which makes the cable have better flexibility and bending performance, and can adapt to various complex installation layouts and bending requirements. The deformable portion including a plurality of protrusions increases the heat dissipation area compared to a straight pipe, improves the heat dissipation efficiency, and further enhances the heat dissipation performance of the charging cable.

[0028] In some exemplary embodiments, the plurality of protrusions may include a plurality of corrugated convex portions spaced apart from each other in the longitudinal direction of the pipe, and the corrugated convex portions extend along the circumferential direction of the pipe.

[0029] In some exemplary embodiments, in the longitudinal sectional view of the pipe, each corrugated convex portion has a V-shaped, U-shaped or trapezoidal shape.

[0030] In some exemplary embodiments, the plurality of protrusions may further include continuous spiral convex portions, and the spiral convex portions extend in a spiral manner around the central axis of the pipe.

[0031] In some exemplary embodiments, the pipe is formed as an outlet pipe, and the charging cable may further include: a plurality of outlet pipes; a plurality of inlet pipes parallel to and fluidly connected to the outlet pipes, and a cooling medium flows into the inlet pipes and flows out through the outlet pipes.

[0032] In some exemplary embodiments, the charging gun includes a charging gun side connector configured to fluidly connect the inlet pipe and the outlet pipe, and the cooling medium from the cooling unit flows into the inlet pipe and enters the outlet pipe through the charging gun side connector, and then flows back to the cooling unit from the outlet pipe.

[0033] In some exemplary embodiments, the charging system includes a charging pile side connector provided at the second end of the charging cable, and the charging pile side connector is configured to fluidly connect the outlet pipe and the inlet pipe to the cooling unit respectively.

[0034] In some exemplary embodiments, the outlet pipe includes a first straight pipe adjacent to the first end, a second straight pipe adjacent to the second end, and a deformable portion provided between the first straight pipe and the second straight pipe. The distance between the center point in the longitudinal direction of the deformable portion and the charging gun is in the range of 1 to 15 meters.

[0035] Through the following detailed description of the exemplary embodiments of the present application in conjunction with the accompanying drawings, the above features and advantages of the present application and other features and advantages will become more apparent. Description of the Drawings

[0036] Referring to the following detailed description of the exemplary embodiments of the present application in conjunction with the accompanying drawings, the above and other objects, features, and advantages of the present application can be more easily understood. In all the drawings, the same or corresponding technical features or components will be represented by the same or corresponding reference numerals. In the drawings, the sizes and relative positions of the various components are not necessarily drawn to scale. In the drawings:

[0037] Figure 1A is a schematic diagram of a charging system according to some exemplary embodiments of the present application;

[0038] Figure 1B is a partial schematic diagram of a charging gun of a charging system according to some exemplary embodiments of the present application;

[0039] Figure 2 is a block diagram of a coolant circuit of a charging system according to some exemplary embodiments of the present application;

[0040] Figures 3A to 3D is a cross-sectional view perpendicular to the length direction of a charging cable according to some exemplary embodiments of the present application;

[0041] Figures 4A to 4I is a schematic diagram of a liquid outlet pipe of a charging cable according to some exemplary embodiments of the present application;

[0042] Figure 5A is a longitudinal cross-sectional view of a spiral portion of a liquid outlet pipe of a charging cable according to some exemplary embodiments of the present application;

[0043] Figure 5B is a longitudinal cross-sectional view of a corrugated portion of a liquid outlet pipe of a charging cable according to some exemplary embodiments of the present application;

[0044] Figure 5C is Figure 5B a schematic diagram of the corrugated portion of the liquid outlet pipe shown in a bent state;

[0045] Figures 6A to 6D is a graph of temperature change of a charging cable under different rated currents according to some exemplary embodiments of the present application.

[0046] Description of the main element reference numerals

[0047] 100. Charging cable (also known as the liquid-cooled cable for new energy equipment); 10. Liquid outlet pipe; 11. Positive liquid outlet pipe; 12. Negative liquid outlet pipe; 13. Corrugated part (also known as corrugated pipe); 14. Spiral part (also known as spiral pipe); 15. Straight pipe; 20. Electric conduction member (also known as core); 30. Liquid inlet pipe; 31. Positive liquid inlet pipe; 32. Negative liquid inlet pipe; 21. Core material; 22. Insulating layer; 40. Sheath; 200. Charging gun; 300. Cooling unit; 230. Charging gun side connector; 210. Charging pile side connector; 1. Charging system. Detailed implementation manners

[0048] The present application will be described in detail below with reference to the accompanying drawings by means of exemplary embodiments. It should be noted that the exemplary embodiments of the present application are intended to enable those of ordinary skill in the art to easily implement the present application. The various embodiments of the present application can be implemented in many different forms and should not be construed as being limited to the embodiments described in the present application. Accordingly, the following detailed description of the present application is for illustrative purposes only and is by no means a limitation of the present application. In addition, the same reference numerals are used in the various drawings to denote the same components. Additionally, the terms "first", "second", etc. are for the purpose of description only and are not to be construed as indicating or implying relative importance or relative order.

[0049] It should also be noted that, for the sake of clarity, not all features of the actual specific embodiments are described and shown in the specification and drawings. Moreover, in order to avoid unnecessary details obscuring the technical solutions of interest in the present application, only the device structures closely related to the technical solutions of the present application are described and shown in the drawings and the specification, while other details that are not closely related to the technical content of the present application and are known to those skilled in the art are omitted.

[0050] Next, an exemplary embodiment of a charging system and a charging cable according to the present application will be described in detail with reference to the accompanying drawings.

[0051] In an exemplary embodiment of the present application, a charging system 1 for an electric vehicle is provided. As Figure 1A 、 Figure 1B and Figure 2 shown, the charging system 1 includes: a charging gun 200; and a charging cable 100 that connects the charging gun 200 to a cooling unit 300. A first end 101 of the charging cable 100 is connected to the charging gun 200, and a second end 103 of the charging cable 100 opposite to the first end 101 is connected to the cooling unit 300. A plurality of electric conduction members of the charging cable 100 are electrically connected to the charging gun 200. The liquid-cooled pipe of the charging cable 100 is in fluid communication with the cooling unit 300.

[0052] Optionally, the charging system 1 may be a charging pile.

[0053] The charging cable 100 may include two power conductors, namely a positive power conductor and a negative power conductor. The charging cable 100 may include a plurality of liquid cooling tubes, and the plurality of liquid cooling tubes include a plurality of inlet tubes 30 and a plurality of outlet tubes 10. In Figure 1A the illustrated embodiment, the inlet tubes 30 include a positive inlet tube 31 and a negative inlet tube 32. The outlet tubes 10 include a positive outlet tube 11 parallel to and in fluid communication with the positive inlet tube 31, and a negative outlet tube 12 parallel to and in fluid communication with the negative inlet tube 32. The positive power conductor is disposed in the positive outlet tube 11, and the negative power conductor is disposed in the negative outlet tube 12. The coolant (also referred to as a cooling medium) flows into the positive inlet tube 31 and the negative inlet tube 32 from the cooling unit 300 and flows out via the positive outlet tube 11 and the negative outlet tube 12. The outlet tube 10 of the present application is provided with a deformable portion or a biasing portion that can be bent (described in detail below).

[0054] The coolant herein may be: oil, ethylene glycol, fluorinated liquid, water, etc.

[0055] In this embodiment, as Figure 1B and Figure 2 shown, the charging gun 200 includes a charging gun side connector 230 that fluidly connects the inlet tube 30 and the outlet tube 10. The cooling medium from the cooling unit 300 flows into the inlet tube 30 and enters the outlet tube 10 via the charging gun side connector 230, and then flows back from the outlet tube 10 to the cooling unit 300. Figures 1A to 2 The arrows in

[0056] indicate the flow direction of the coolant. Figure 3A and Figure 3B In this embodiment, as

[0057] shown, the outlet tube 10 is divided into a positive outlet tube 11 corresponding to the positive power conductor 20A (also referred to as the positive core) and a negative outlet tube 12 corresponding to the negative power conductor 20B (also referred to as the negative core), ensuring that the coolant can cool the positive power conductor 20A and the negative power conductor 20B respectively. Similarly, the inlet tube 30 is also divided into a positive inlet tube 31 and a negative inlet tube 32 for supplying coolant to the positive outlet tube 11 and the negative outlet tube 12 respectively.

[0057] As Figure 1A shown, the charging system 1 may further include a charging pile side connector 210 disposed at the second end portion 103 of the charging cable. The charging pile side connector 210 is configured to fluidly connect the inlet tube 30 and the outlet tube 10 to the cooling unit 300 respectively.

[0058] In some exemplary embodiments, the cooling unit 300 of the charging system 1 may include a circulation pump (not shown) for circulating a coolant within the charging cable. For example, one end of each of the positive inlet pipe 31 and the negative inlet pipe 32 is connected to the output end of the circulation pump via the charging pile side connector 210. The other end of each of the positive inlet pipe 31 and the negative inlet pipe 32 is connected to the corresponding coolant inlet of the charging gun side connector 230 of the charging gun 200. One end of each of the positive outlet pipe 11 and the negative outlet pipe 12 is connected to the corresponding coolant outlet of the charging gun side connector 230. The other end of each of the positive outlet pipe 11 and the negative outlet pipe 12 is connected to the input end of the circulation pump via the charging pile side connector 210. The coolant circulates through the circulation pump within the charging cable 100 between the cooling unit 300 and the charging gun 200 to cool down.

[0059] When the charging gun 200 starts to work, as Figure 1A and Figure 2 shown by the arrows, the coolant from the cooling unit 300 enters the positive inlet pipe 31 and the negative inlet pipe 32, and respectively enters the positive outlet pipe 11 and the negative outlet pipe 12 via the charging gun side connector 230. The coolant flows within the outlet pipes 11 and 12, closely surrounding the power conduction member 20, absorbing and carrying away the heat generated by the power conduction member 20. The coolant returns to the cooling unit 300 through the outlet pipe 10 to complete a cooling cycle. This process continues to ensure that the cable always remains at a lower temperature.

[0060] Optionally, the cooling unit 300 of the charging system 1 is further provided with a heat exchanger (or radiator), a cooling system controller, and a cooling fan. The heat exchanger and the cooling fan are used to reduce the temperature of the coolant flowing through the charging pile, so as to reduce the overall temperature of the coolant flowing through the charging cable.

[0061] Since a large amount of heat is generated during the charging process, if the heat cannot be dissipated in time, it will lead to a decrease in the charging speed and even affect the service life of the charging gun 200. By respectively cooling the positive power conduction member and the negative power conduction member through the positive outlet pipe 11 and the negative outlet pipe 12 in the charging cable 100, it can be ensured that the power conduction member 20 always remains at a lower temperature, thereby improving the charging efficiency. The design of the charging cable in this application can significantly reduce the operating temperature of the cable, thereby extending its service life.

[0062] It should be understood that the charging cable design of the present application is particularly suitable for new energy devices that require long-term and high-load operation. For example, the charging cable 100 of the present application is particularly suitable for places such as electric vehicle charging stations and public parking lots that require high power and fast charging. In some examples, in the charging facilities of electric vehicles, the charging gun 200 needs to withstand a working environment of high current and high temperature. By continuously supplying the coolant through the above cooling circulation loop, the working temperature of the cable of the charging gun 200 can be effectively reduced, and the charging efficiency and safety can be improved. In addition, in addition to being applied to new energy devices (such as electric vehicles), the charging cable of the present application can also be connected to other devices under high power and / or high temperature conditions to achieve signal transmission or power transmission. For example, the charging cable of the present application can be connected to a data center with a high-power graphics processor to implement machine learning.

[0063] Figures 3A to 3D is a cross-sectional view perpendicular to the length direction of the charging cable according to some exemplary embodiments of the present application. In Figure 3A and Figure 3B In the illustrated embodiment, the charging cable 100 may include: a positive power conductor 20A, a negative power conductor 20B, a positive liquid inlet pipe 31, a negative liquid inlet pipe 32, a positive liquid outlet pipe 11 parallel to and in fluid communication with the positive liquid inlet pipe 31, and a negative liquid outlet pipe 12 parallel to and in fluid communication with the negative liquid inlet pipe 32.

[0064] It should be understood that the liquid inlet pipe 30 serves as an inlet for the coolant to ensure that the coolant can enter the charging cable stably and smoothly. By reasonably designing the diameter and flow rate of the liquid inlet pipe 30, the flow velocity and flow rate of the coolant can be optimized, and the heat dissipation efficiency can be improved.

[0065] The liquid outlet pipe 10 directly bears the flowing coolant and guides the coolant around the power conductor 20. By optimizing the structure and material of the liquid outlet pipe 10, the contact area between the coolant and the power conductor 20 can be increased, and the heat dissipation effect can be improved. At the same time, the liquid outlet pipe 10 has high strength and corrosion resistance to ensure the long-term stable operation of the cable.

[0066] The positive power conductor 20A is disposed in the positive liquid outlet pipe 11, and the negative power conductor 20B is disposed in the negative liquid outlet pipe 12. Placing the power conductor 20 directly inside the liquid outlet pipe 10 enables the power conductor 20 to directly contact the coolant, thereby quickly transferring heat to the coolant. This design method improves the heat conduction efficiency, reduces the temperature of the wire core, and effectively prevents the power conductor from being damaged or its performance from deteriorating due to overheating. The liquid inlet pipe 30 and the liquid outlet pipe 10 are arranged side by side, which is beneficial to the overall layout and structural optimization of the cable and reduces the occupied space of the cable.

[0067] Such as Figure 3A andFigure 3B As shown, in a cross-section of the charging cable 100 perpendicular to the length direction, the positive liquid inlet pipe 31 and the negative liquid inlet pipe 32 can be arranged on the same side of the connection line connecting the center of the positive power conductor 20A and the center of the negative power conductor 20B. The nominal cross-sectional area of the wire core of each power conductor among the multiple power conductors is within 16 mm 2 to 240 mm 2 . Optionally, the nominal cross-sectional area of the wire core of each power conductor is 25 mm 2 or 35 mm 2 . Optionally, the nominal cross-sectional area of the wire core of each power conductor is 2 AWG (American Wire Gauge).

[0068] The charging cable 100 may further include a ground wire 60, and the nominal cross-sectional area of the wire core of the ground wire is within 2 mm 2 to 100 mm 2 . Optionally, the nominal cross-sectional area of the wire core of the ground wire 60 is 2 mm 2 . Optionally, the nominal cross-sectional area of the wire core of the ground wire 60 is 14 AWG or 12 AWG.

[0069] The charging cable 100 may further include a plurality of signal wires 50, and the nominal cross-sectional area of the wire core of each signal wire in the signal wires 50 is within 0.5 mm 2 to 2.5 mm 2 . Optionally, the nominal cross-sectional area of the wire core of the signal wire 50 is 0.5 mm 2 or 0.75 mm 2 . Optionally, the nominal cross-sectional area of the wire core of the signal wire 50 is 18 AWG or 20 AWG.

[0070] In the Figure 3A embodiment shown, the charging cable 100 may further include a sheath 40, and the liquid outlet pipe 10 and the liquid inlet pipe 30 are both located within the sheath 40. The sheath 40 is located on the outermost layer of the charging cable to provide protection for each inner cable. The primary function of the sheath 40 is to protect the inner liquid outlet pipe 10 and liquid inlet pipe 30 from damage by the external environment. In practical applications, the cable may encounter various complex physical and chemical environments, such as friction, impact, corrosion, etc. The sheath 40 can provide a strong outer shell to reduce the damage of these external factors to the internal structure of the cable.

[0071] The sheath 40 can enhance the overall structural stability of the cable. By wrapping and fixing the liquid outlet pipe 10 and the liquid inlet pipe 30, the sheath 40 ensures the relative position between them is stable and prevents displacement or deformation during use.

[0072] In addition, the design of the sheath 40 is usually also considered to improve the appearance of the cable. A neat and smooth sheath 40 can make the cable look more professional and high-end, and enhance the overall image of the product.

[0073] In addition, by protecting the liquid outlet pipe 10 and the liquid inlet pipe 30 from external damage, the sheath 40 can extend the service life of the cable. The cable with a stable structure is safer and more reliable during use, reducing the potential safety hazards caused by structural problems. The beautiful appearance of the cable can enhance the user experience and increase the market competitiveness of the product.

[0074] In summary, during the manufacturing process, the sheath 40 is formed by a specific process (such as extrusion, injection molding, etc.) and tightly wrapped around the outer periphery of the liquid outlet pipe 10 and the liquid inlet pipe 30. During use, the sheath 40 always plays a protective role, whether the cable is bent, stretched or subjected to external impact, the sheath 40 can effectively protect the internal pipeline structure.

[0075] In some examples, the charging cable 100 may include fillers between the wires. Optionally, the charging cable is further provided with a metal shielding layer, which is provided on the outer side of the signal wire or the outer side of the filling layer, and can effectively block the influence of electromagnetic waves, noise, etc. on the charging cable, and ensure normal signal transmission.

[0076] exist Figure 3A In the illustrated embodiment, the power conductor (core) 20 may include: a core material 21 and an insulating layer 22 covering the core material 21. The liquid outlet pipe 10 is located on the side of the insulating layer 22 away from the core material 21. The coolant flows between the insulating layer 22 and the liquid outlet pipe 10 to take away the heat generated by the core material 21.

[0077] Specifically, the core material 21 serves as the core part of the cable, and the core material 21 is mainly made of metal materials with good electrical conductivity, such as copper or aluminum. Its main function is to transmit current and ensure the stable transmission of power or signals. The insulating layer 22 is tightly wrapped around the periphery of the core material 21. Optionally, the insulating layer 22 is usually made of polymer materials such as polyethylene, polyvinyl chloride, etc. The main function of the insulating layer 22 is to prevent the core material 21 from contacting the external environment, prevent current leakage or external factors from interfering with current transmission, and ensure the safe operation of the cable. The power conductor 20 is placed directly inside the liquid outlet pipe 10, so that it can directly contact the flowing coolant to achieve efficient heat conduction.

[0078] The liquid outlet pipe 10 is a specially designed pipe located outside the insulation layer 22. It is made of fluoroplastic material, which has good corrosion resistance and high temperature resistance, and is suitable for use in complex electrical environments. In some examples, the liquid outlet pipe 10 can be designed to include a corrugated pipe 13 or a spiral pipe 14, or be composed of a combination of a straight pipe 15 and a corrugated pipe 13 / spiral pipe 14 (described in detail below). These designs all help to increase the surface area of the pipe and improve the cooling effect.

[0079] When the cable starts to work, current flows through the core material 21 and generates heat. This heat is first absorbed and dissipated by the insulation layer 22. At the same time, the coolant flows inside the liquid outlet pipe 10. When the coolant contacts the outer surface of the insulation layer 22, it begins to absorb the heat on the insulation layer 22. Since the liquid outlet pipe 10 is made of fluoroplastic and designed with a corrugated part 13 or a spiral part 14, the contact area with the coolant is increased, thus improving the efficiency of heat transfer. After the coolant absorbs heat, it flows back to the cooling unit through the liquid outlet pipe 10 for circulating cooling.

[0080] In this process, the flow of the coolant is continuous. It continuously takes away the heat from the insulation layer 22, preventing the heat from accumulating on the insulation layer 22 and the core material 21. This can effectively control the temperature of the cable, prevent various electrical faults caused by overheating, and ensure the stable operation of the cable.

[0081] In Figure 3C In an exemplary embodiment of the charging cable shown, in a cross-section perpendicular to the length direction of the charging cable 100, the positive liquid inlet pipe 31 and the negative liquid inlet pipe 32 can be arranged on opposite sides of the connecting line connecting the center of the positive power conducting member 20A and the center of the negative power conducting member 20B.

[0082] In Figure 3D In the exemplary embodiment of the charging cable described, the power conducting members of the charging cable 100 include two positive power conducting members 20A and two negative power conducting members 20B. The liquid cooling pipes can include two liquid inlet pipes and four liquid outlet pipes. Specifically, the liquid inlet pipe 30 includes a positive liquid inlet pipe 31 and a negative liquid inlet pipe 32. The liquid outlet pipe 10 includes: two positive liquid outlet pipes 11 that are parallel to and in fluid communication with the positive liquid inlet pipe 31; and two negative liquid outlet pipes 12 that are parallel to and in fluid communication with the negative liquid inlet pipe 32. The two positive power conducting members 20A are respectively arranged in the two positive liquid outlet pipes 11. The two negative power conducting members 20B are respectively arranged in the two negative liquid outlet pipes 12. The coolant flows into the positive liquid inlet pipe 31 and the negative liquid inlet pipe 32 and flows out through the corresponding liquid outlet pipes.

[0083] In Figure 3D In the embodiment shown, the nominal cross-sectional area of the wire core of each power conducting member is 25 mm2 or 35mm 2 。Optionally, the nominal cross-sectional area of the core of each power conductor is 2AWG. The charging cable 100 may also include a ground wire 60, which is disposed at a substantially central position of the charging cable 100. The nominal cross-sectional area of the core of the ground wire 60 is 25mm 2 。Optionally, the nominal cross-sectional area of the core of the ground wire 60 is 3AWG.

[0084] The charging cable 100 also includes a plurality of signal lines 50. Optionally, the nominal cross-sectional area of the core of the signal line 50 is 0.5mm 2 or 0.75mm 2 。Optionally, the nominal cross-sectional area of the core of the signal line 50 is 18AWG or 20AWG. The charging cable 100 also includes a plurality of communication lines. Optionally, the nominal cross-sectional area of the core of the communication line is 1mm 2 。

[0085] It should be understood that the number, size, and arrangement of the power conductors, ground wires, signal lines, communication lines, etc. of the charging cable 100 are not limited to the embodiments described above by way of example, but can be adjusted according to actual situations. The charging cable of the present application complies with the relevant regulations on charging cables in the national standards "Connection Devices for Conductive Charging of Electric Vehicles" (GB / T 20234.4-2023) and "Cables for Electric Vehicle Charging" (GB / T 33594-2017).

[0086] Next, an exemplary description of the liquid outlet pipe 10 of the charging cable 100 of the present application will be given in conjunction with Figures 4A to 4I 。

[0087] As Figure 4A shown, the liquid outlet pipe 10 surrounds the power conductor 20. A cooling medium channel for the circulation of the cooling medium is formed between the outer peripheral surface of the power conductor 20 and the inner peripheral surface of the liquid outlet pipe 10. The liquid outlet pipe 10 includes a first straight pipe 10A adjacent to the first end of the cable, a second straight pipe 10B adjacent to the second end of the cable, and a deformable portion 10C disposed between the first straight pipe 10A and the second straight pipe 10B. The distance between the center point in the length direction of the deformable portion 10C and the charging gun 200 can be in the range of 1 to 15 meters.

[0088] In an alternative embodiment, the deformable portion 10C can be at least one of a corrugated portion (also known as a corrugated pipe) 13 or a helical portion (also known as a helical pipe) 14. The length of the deformable portion 10C can be 1% to 100% of the length of the liquid outlet pipe 10. Optionally, the length of the deformable portion 10C is approximately 20% to 80% of the length of the liquid outlet pipe 10.

[0089] As Figures 4A to 4IAs shown, the liquid outlet pipe 10 includes either a corrugated portion 13 or a helical portion 14, or a combination of both. In some exemplary embodiments, one section of the liquid outlet pipe 10 is a straight pipe 15, and the other section is either a corrugated portion 13 or a helical portion 14, or a combination of both.

[0090] The liquid outlet pipe 10 adopts the design of a corrugated portion 13 or a helical portion 14, or a combined design of a straight pipe 15 and a corrugated portion 13 or a helical portion 14. The design of the corrugated portion 13 or the helical portion 14 enables the cable to have better flexibility and bending performance, and can adapt to various complex installation layouts and bending requirements. The corrugated or threaded structure increases the surface area of the liquid outlet pipe 10, improves the flow rate of the coolant and the heat dissipation efficiency, and further enhances the heat dissipation performance of the cable.

[0091] The combined design of the straight pipe 15 and the corrugated portion 13 or the helical portion 14 ensures that the cable has sufficient rigidity in some parts that require stable support, and provides good flexibility in the parts that need to be bent. During the equipment wiring process, the cable can be bent and twisted according to actual needs. The design of the corrugated portion 13 or the helical portion 14 enables the cable to easily cope with these deformations while maintaining the smooth circulation of the internal coolant. This design is particularly suitable for devices that need to be frequently bent or moved, such as the charging cable of an electric vehicle, the power transmission line of a robot arm, etc.

[0092] In some exemplary embodiments, the liquid inlet pipe 30 can be a straight pipe. In an alternative embodiment, the liquid inlet pipe 30 can be configured to include a corrugated portion 13 and / or a helical portion 14.

[0093] In some examples, the liquid inlet pipe 30 and / or the liquid outlet pipe 10 are made of fluoroplastic.

[0094] The maximum temperature that the charging cable including the above-mentioned liquid outlet pipe can withstand during operation in this application is about 180 degrees. In comparison, in the related art, the maximum temperature that a cable including a liquid outlet pipe made of a cross-linked material can withstand during operation is about 85 degrees. The maximum temperature that a cable including a liquid outlet pipe made of nylon material can withstand during operation is about 125 degrees.

[0095] The high corrosion resistance of fluoroplastic can ensure that the liquid cooling pipe will not be eroded by the coolant during long-term use. The high temperature resistance of fluoroplastic guarantees that the liquid cooling pipe can still maintain stable performance in a high-temperature working environment. In addition, the good insulation of fluoroplastic helps to ensure the overall safety of the cable.

[0096] Through the structural design of the liquid outlet pipe 10, the liquid inlet pipe 30, the power conduction member 20, and the corrugated part 13 or the helical part 14, the charging cable 100 achieves efficient heat dissipation, corrosion resistance, excellent insulation performance, and good flexibility, providing strong support for the stable operation of new energy devices. These characteristics enable the cable to adapt to various complex working environments and meet the requirements of new energy devices for high efficiency, safety, and reliability.

[0097] In Figures 4A to 4I In each of the embodiments of the liquid outlet pipe shown, the deformable part of the liquid outlet pipe 10 includes one or both of a corrugated part and a helical part.

[0098] In Figure 4B and Figure 4C In the embodiments shown, the liquid outlet pipe 10 in the charging cable 100 of the present application is composed of the corrugated part 13 or the helical part 14.

[0099] Specifically, as the main channel for the coolant to flow in the liquid-cooled cable, the design of the liquid outlet pipe 10 is crucial for the cooling effect and overall performance of the cable. The corrugated part 13 (also called corrugated pipe) of the present application is a pipe with a continuous waveform structure, and both its interior and exterior exhibit regular corrugations. This structure endows the corrugated pipe 13 with good flexibility, enabling it to easily handle the bending and twisting that the cable may encounter during use. At the same time, the corrugated structure also increases the surface area of the pipe, contributing to enhancing the heat dissipation effect of the coolant.

[0100] The pipe surface of the helical part 14 (also called helical pipe) of the present application has a thread-like concave-convex structure. This structure not only enhances the mechanical strength of the pipe but also increases the contact area between the pipe and the coolant to a certain extent, thereby improving the cooling efficiency. In addition, the helical part 14 also has good flexibility and can adapt to the bending requirements of the cable.

[0101] Next, refer to Figures 5A to 5C to illustrate the structures of the corrugated part 13 and the helical part 14 of the present application.

[0102] Figure 5A It is a longitudinal sectional view of the helical part 14 of the liquid outlet pipe 10 of the charging cable according to some exemplary embodiments of the present application.

[0103] The helical portion 14 may include a helical convex portion 140 that extends in a helical manner around the central axis of the liquid outlet pipe 10. In a longitudinal sectional view of the liquid outlet pipe 10, the helical portion 14 includes a plurality of protruding portions (such as protruding cavities) that protrude in the radial direction of the liquid outlet pipe 10, and the protruding portions are formed by the helical convex portion 140, with a gap S between adjacent protruding portions. The plurality of protruding portions are configured such that when the charging cable 100 is bent, the gap S changes under the action of the bending force to accommodate the relative movement of the adjacent protruding portions. Optionally, the plurality of protruding portions arranged in a linear array along the length direction of the liquid outlet pipe 10 may be the same. The design of the gap between two adjacent protruding portions allows the degree of bending of the liquid outlet pipe 10 to increase, so that the liquid outlet pipe can adapt to the bending and twisting of the charging cable.

[0104] Optionally, in a longitudinal sectional view of the liquid outlet pipe 10, the protruding portions of the helical portion 14 may be in a V-shaped, U-shaped or trapezoidal shape.

[0105] It should be understood that the longitudinal section of the liquid outlet pipe 10 herein refers to the cross-section of the liquid outlet pipe 10 in the length direction.

[0106] In some exemplary embodiments, as Figure 5A shown, each of the plurality of liquid outlet pipes 10 includes a biasing portion, and in a longitudinal sectional view of the pipe 10, the distance d in the radial direction of the liquid outlet pipe 10 between the inner peripheral surface of the biasing portion and the central axis A-A of the corresponding power conduction member 20 changes along the length direction of the pipe 10. The biasing portion may correspond to a radially outward protruding portion.

[0107] The biasing portion includes a plurality of corrugated portions 13 and / or a plurality of helical portions 14.

[0108] In some exemplary embodiments, the length of the biasing portion can be designed according to actual needs. For example, the length of the biasing portion can be 1% to 100% of the length of the liquid outlet pipe. Optionally, the length of the biasing portion is 20% to 80% of the length of the liquid outlet pipe.

[0109] The minimum bending radius of the biasing portion is in the range of 4 to 10 times the outer diameter of the liquid outlet pipe 10, and the minimum bending radius of the charging cable 100 is in the range of 4 to 10 times the outer diameter of the charging cable 100.

[0110] In some exemplary embodiments, the outer diameter of the liquid-cooled charging cable 100 may be in the range of 20 mm to 70 mm. Compared with non-liquid-cooled charging cables, the charging cable of the present application improves the heat dissipation efficiency and can use thinner wires to carry the same current. This not only reduces the weight of the cable but also decreases the volume of the cable, making it more lightweight and flexible, while reducing the manufacturing and transportation costs of the charging cable.

[0111] Figure 5B FIG. 4 is a longitudinal sectional view of a corrugated portion 13 of a liquid outlet pipe 10 of a charging cable according to some exemplary embodiments of the present application. Figure 5C is Figure 5B FIG. 5 is a schematic view of the corrugated portion 13 shown in a bent state.

[0112] The corrugated portion 13 includes a plurality of corrugated convex portions 130 arranged at intervals from each other. Each corrugated convex portion 130 extends along the circumferential direction of the liquid outlet pipe 10. The corrugated convex portions 130 may be formed to be spaced apart from each other at a constant pitch or at a variable pitch in the longitudinal direction of the liquid outlet pipe.

[0113] In some embodiments of the present application, in the longitudinal sectional view of the corrugated portion 13, each corrugated convex portion 130 may be in a V-shape, a U-shape or a trapezoidal shape.

[0114] As Figure 5B shown, in the longitudinal sectional view of the liquid outlet pipe 10, the corrugated portion 13 may include a plurality of protruding portions 130 (such as protruding cavities) protruding along the radial direction of the liquid outlet pipe 10, with a gap S between adjacent protruding portions. The plurality of protruding portions are configured such that, when the charging cable 100 is bent, the gap S changes under the action of the bending force to accommodate the relative movement of the adjacent protruding portions. Optionally, the plurality of protruding portions arranged in a linear array along the longitudinal direction of the liquid outlet pipe 10 may be the same. When the corrugated portion 13 is bent, two adjacent protruding portions among the plurality of protruding portions move relative to each other under the action of the bending force, and the design of the concave gap between the two adjacent protruding portions allows the degree of bending of the liquid outlet pipe 10 to increase, so that the liquid outlet pipe 10 can be easily bent to adapt to the bending and twisting of the charging cable 100.

[0115] Through the liquid outlet pipe 10 provided by the present application, which is composed of several corrugated portions 13 or helical portions 14, the overall flexibility of the charging cable is significantly improved. This enables the cable to easily cope with various bending and twisting scenarios, such as the frequent movement and bending of the charging gun 200 of new energy vehicles, ensuring the stability and reliability of the cable.

[0116] Meanwhile, the concave-convex structure design of the corrugated portion 13 and the helical portion 14 increases the contact area between the pipe and the coolant, thereby improving the heat dissipation efficiency. This helps to more quickly and effectively carry away the heat generated by the power conducting member 20, ensuring the stable operation of the cable in a high-temperature environment.

[0117] In some embodiments, the corrugated portion 13 and the helical portion 14 can both be manufactured independently and then quickly connected. The modularly designed corrugated portion 13 and helical portion 14 can be conveniently combined and connected according to actual needs, thus simplifying the manufacturing process. At the same time, this design also reduces the manufacturing cost and improves the production efficiency.

[0118] In addition, the corrugated portion 13 and the helical portion 14 have high structural strength and can resist external pressure and impact. Moreover, the good flexibility and heat dissipation performance of the corrugated portion 13 and / or the helical portion 14 also contribute to extending the service life of the cable and improving the overall reliability.

[0119] In summary, in practical applications, the coolant enters the liquid outlet pipe 10 composed of several sections of the corrugated portion 13 or the helical portion 14 through the liquid inlet pipe 30. When flowing through each pipe section, the coolant exchanges heat with the insulating layer 22 on the power transmission wire 20 and carries away the heat generated by the power transmission wire 20. Due to the special structure of the corrugated portion 13 and the helical portion 14, the flow of the coolant in the pipe is more uniform and sufficient, thus achieving an efficient heat dissipation effect.

[0120] As the cable bends and moves, each pipe section in the liquid outlet pipe 10 will also bend and twist accordingly. Since the corrugated portion 13 and the helical portion 14 have good flexibility, they can easily cope with these deformations, ensuring the continuity and stability of the coolant flow.

[0121] In Figure 4D the described embodiment, the liquid outlet pipe 10 is formed by connecting a straight pipe 15 and a corrugated portion 13. In Figure 4E the described embodiment, the liquid outlet pipe 10 is formed by connecting a straight pipe 15 and a helical portion 14.

[0122] In Figures 4D to 4E the shown embodiment, the straight pipe 15 is usually used to ensure the overall structure and strength of the cable, especially in situations where the cable needs to maintain a certain shape or rigidity. The straight pipe 15 can also serve as a connection part of the cable, facilitating connection with other components or devices. The design of the straight pipe 15 makes the installation and maintenance of the liquid inlet pipe 30 more convenient. During the installation process, the straight pipe 15 is easier to dock with the charging pile side connector 210 and other components. During maintenance, the structure of the straight pipe 15 is simple, facilitating inspection and replacement. The material of the straight pipe 15 can be selected as composite cross-linked pipe material.

[0123] The corrugated portion 13 or the helical portion 14 is mainly used to enhance the heat dissipation performance of the cable. Due to its special wave shape, the corrugated portion 13 can increase the contact area with the coolant and improve the heat dissipation efficiency. The helical portion 14, through its helical structure, forms more flow channels, which helps the flow and heat dissipation of the coolant.

[0124] By combining the design of the straight pipe 15 and the corrugated portion 13 or the helical portion 14, both the structural stability of the cable and its heat dissipation performance are significantly improved. Especially in high-load and high-temperature working environments, this design can effectively prevent the cable from overheating and extend the service life of the cable. Due to the combination of the different characteristics of the straight pipe 15 and the corrugated portion 13 or the helical portion 14, the cables designed in this way can adapt to a wider variety of working environments and installation requirements. Whether it is a situation where a certain shape needs to be maintained or a situation where heat dissipation performance needs to be enhanced, suitable application scenarios can be found. Compared with the design that uses the corrugated portion 13 or the helical portion 14 throughout, this combined design can reduce the material cost while ensuring performance, thereby improving the competitiveness of the product.

[0125] During use, the coolant enters the liquid outlet pipe 10 of the cable through the liquid inlet pipe 30. In the straight pipe 15 section, the coolant maintains a stable flow state. When the coolant enters the corrugated portion 13 or the helical portion 14, due to its special shape and structure, the flow of the coolant becomes more complex and turbulent, thereby increasing the contact area with the cable and the heat dissipation effect. Through this design, the coolant can more effectively take away the heat generated by the power conduction member 20 and ensure the stable operation of the cable.

[0126] In Figure 4F and Figure 4I the shown embodiment, the combined use of the corrugated portion 13 and the helical portion 14 can significantly improve the performance of the cable. Especially in high-load and high-temperature working environments, it can effectively extend the service life of the cable. Through the combined design, the cable can adapt to more working environments and provide flexible solutions for various application scenarios. Compared with the single use of high-cost special pipes, the combined use of the corrugated portion 13 and the helical portion 14 can reduce the material cost on the premise of ensuring performance, thereby improving the competitiveness of the product.

[0127] During use, the coolant enters the liquid outlet pipe 10 through the liquid inlet pipe 30 and flows within the liquid outlet pipe 10. Since the liquid outlet pipe 10 is composed of several corrugated parts 13 and several helical parts 14 combined, when the coolant flows through different sections, it will receive different heat dissipation effects. The special shape of the corrugated part 13 section can increase the contact area with the coolant and improve the heat exchange efficiency; while the thread structure of the helical part 14 section can further enhance the heat dissipation effect. Through this combined design, the liquid outlet pipe 10 can achieve efficient heat dissipation as a whole, ensuring that the temperature of the power conduction member 20 is always maintained within a safe range.

[0128] In Figure 4G the illustrated embodiment, the liquid outlet pipe 10 is formed by connecting several straight pipes 15 and several corrugated parts 13. In Figure 4H the illustrated embodiment, the liquid outlet pipe 10 is formed by connecting several straight pipes 15 and several helical parts 14. In Figure 4I the illustrated embodiment, the liquid outlet pipe 10 is formed by connecting several straight pipes 15, several corrugated parts 13 and several helical parts 14.

[0129] In Figures 4G to 4I the illustrated embodiment, the straight pipe 15 part is mainly used to maintain the overall structural stability of the cable, especially in application scenarios where the cable needs to maintain a straight line or a specific shape. The straight pipe 15 also provides a good fluid channel to ensure that the coolant can flow smoothly. As mentioned above, the corrugated part 13 part increases the contact area with the coolant through its unique waveform structure, thereby improving the heat dissipation efficiency. In addition, the corrugated part 13 also has a certain flexibility and can adapt to the deformation of the cable when it is bent or twisted. The helical part 14 part enhances the fluidity and mixing effect of the coolant through its helical structure, further improving the heat dissipation performance. At the same time, the helical part 14 also has a certain structural strength and can support the overall structure of the cable.

[0130] When the liquid outlet pipe 10 includes multiple corrugated parts 13 and / or multiple helical parts 14, it means that the liquid outlet pipe 10 is not a pipe with a constant cross-section, but is composed of multiple different pipe segments connected in a certain way (such as connectors or integrated molding techniques).

[0131] According to Figures 4G to 4IIn the described embodiment, during use, the coolant enters the liquid outlet pipe 10 of the cable through the liquid inlet pipe 30. In the straight pipe 15 section, the coolant maintains a stable flow state; when the coolant enters the corrugated section 13 or the spiral section 14, due to its special shape and structure, the flow of the coolant becomes more complex and turbulent, increasing the turbulence degree of the coolant, providing a larger heat exchange area, and thus improving the heat transfer efficiency. Through this design, the coolant can more effectively take away the heat generated by the power conduction member 20, ensuring the stable operation of the cable.

[0132] In practical applications, the coolant enters the liquid outlet pipes 11 and 12 composed of several corrugated sections 13 and / or spiral sections 14 through the positive liquid inlet pipe 31 and the negative liquid inlet pipe 32. When flowing through each pipe section, the coolant exchanges heat with the power conduction member 20, taking away the heat generated by the power conduction member 20. Due to the special structure of the corrugated section 13 and / or the spiral section 14, the flow of the coolant in the pipeline is more uniform and sufficient, thus achieving an efficient heat dissipation effect. In addition, the corrugated section 13 and the spiral section 14 can compensate for the thermal deformation of the liquid outlet pipe 10 caused by temperature changes, thereby reducing the stress and stress concentration in the pipeline.

[0133] In some embodiments of the present application, the minimum bending radius of the deformable part (such as the corrugated section 13 and / or the spiral section 14) is in the range of 4 to 10 times the outer diameter of the liquid outlet pipe. The minimum bending radius of the charging cable is in the range of 4 to 10 times the outer diameter of the charging cable.

[0134] The bending radius of the cable described herein refers to the arc radius to which the cable can be safely bent without damaging its internal conductor and insulating layer. This parameter affects the service life and reliability of the electric vehicle charging cable. The smaller the bending radius of the cable, the higher the degree of bending.

[0135] It should be understood that the liquid outlet pipe of the charging cable of the present application is not limited to Figures 4A to 4I the described embodiment, but the size and arrangement of the deformable part or the offset part of the liquid outlet pipe can be adjusted according to actual needs.

[0136] Figures 6A to 6DThe figure shows a graph of the temperature change of a charging cable according to some exemplary embodiments of the present application under different rated DC currents. A coolant (such as oil) is supplied at a rate of 2 liters per minute (2 LPM). The charging cable of the present application includes a plurality of tubes, each tube surrounding a power transmission wire, and each tube includes a deformable or biased portion (such as a helical portion and a corrugated portion) that can be bent. The graph shown includes the temperature change curves over time of the DC positive terminal and the DC negative terminal of the charging socket disposed in an electric vehicle, which are electrically connected to the charging gun and are of a non-liquid-cooled type, and are used here as a comparative example. It should be understood that in Figures 6A to 6D In the graph shown, the temperature curve of the DC positive terminal basically coincides with the temperature curve of the DC negative terminal.

[0137] Figure 6A The figure shows a graph of the temperature change of a charging cable according to some exemplary embodiments of the present application under a rated DC current of 500 A. During the period when the charging cable 100 operates for about 60 minutes to 120 minutes, the temperature of the DC negative terminal of the charging socket is in the range of about 65 degrees to 70 degrees (refer to curve C505). In comparison, during the period when the charging cable operates for about 60 minutes to 120 minutes, the temperature of the DC negative busbar (DC negative power transmission member) of the charging cable of the present application is in the range of 50 to 55 degrees (refer to curve C507). The temperature of the DC positive busbar (DC positive power transmission member) of the charging cable of the present application is in the range of 45 to 50 degrees (refer to curve C506).

[0138] Figure 6B The figure shows a graph of the temperature change of a charging cable according to some exemplary embodiments of the present application under a rated DC current of 600 A. During the period when the charging cable 100 operates for about 60 minutes to 120 minutes, the temperature of the DC negative terminal of the charging socket is about 80 degrees (refer to curve C605). In comparison, during the period when the charging cable operates for about 60 minutes to 120 minutes, the temperature of the DC negative busbar (DC negative power transmission member) of the charging cable of the present application is about 60 degrees (refer to curve C607). The temperature of the DC positive busbar (DC positive power transmission member) of the charging cable of the present application is in the range of 55 to 60 degrees (refer to curve C606).

[0139] Figure 6CShows the temperature change curve of the charging cable according to some exemplary embodiments of the present application under the application of a rated DC current of 700 A. During the period when the charging cable 100 operates for about 60 minutes to 120 minutes, the temperature of the DC negative pole of the charging socket is between about 95 and 100 degrees (refer to curve C705). In comparison, during the period when the charging cable operates for about 60 minutes to 120 minutes, the temperature of the DC negative pole copper bar (DC negative pole power conductor) of the charging cable of the present application is about 70 degrees (refer to curve C707). The temperature of the DC positive pole copper bar (DC positive pole power conductor) of the charging cable of the present application is in the range of about 65 to 70 degrees (refer to curve C706).

[0140] Figure 6D Shows the temperature change curve of the charging cable according to some exemplary embodiments of the present application under the application of a rated DC current of 800 A. During the period when the charging cable 100 operates for about 60 minutes to 120 minutes, the maximum temperatures of the DC negative pole and the DC positive pole of the charging socket are between 100 and 130 degrees (refer to curves C804 and C805). In comparison, during the period when the charging cable operates for about 60 minutes to 120 minutes, the temperature of the DC negative pole copper bar (DC negative pole power conductor) of the charging cable of the present application is about 80 degrees (refer to curve C807). The temperature of the DC positive pole copper bar (DC positive pole power conductor) of the charging cable of the present application is in the range of about 70 to 80 degrees (refer to curve C806).

[0141] According to Figures 6A to 6D The shown curve graph, it can be seen that when a rated DC current of 500 A to 800 A is applied to the power conductor (such as a copper bar), the temperature of the power conductor of the charging cable of the present application is in the range of about 50 degrees to 85 degrees. Compared with non-liquid-cooled types of charging sockets, the operating temperature of the power conductor of the charging cable of the present application is greatly reduced. The charging cable according to the exemplary embodiments of the present application can more effectively remove the heat generated by the wire core, ensuring the stable operation of the cable. The charging cable can improve the heat dissipation efficiency, thereby increasing the charging speed and at the same time increasing the service life of the cable.

[0142] Due to the good heat dissipation performance of the charging cable of the present application, the charging cable can not only be applied to the new energy vehicle charging gun 200, but also be widely applied to other high-power, high-load or high-integration electrical equipment. For example, in wind power generation and photovoltaic power generation systems, since the equipment needs to operate for a long time and at a high load, traditional cables are easily damaged due to overheating. By using this liquid-cooled cable, the heat dissipation problem can be effectively solved, improving the operating stability and service life of the equipment.

[0143] In addition, with the rapid development of new energy fields such as electric vehicles and smart grids, the demand for efficient and safe cables is also increasing. As a new type of heat dissipation solution, this charging cable has broad market prospects and application potential.

[0144] According to some exemplary embodiments of the present application, a liquid-cooled cable for new energy equipment is also provided, in which the wire core is cooled by flowing coolant, and the cable includes: a liquid-cooling tube through which the coolant passes and a wire core located in the liquid-cooling tube; and when observed along any radial direction of the liquid-cooling tube, the liquid-cooling tube is any one of a straight tube, a corrugated tube or a spiral tube, or a combination of any two of the three, or a combination of the three.

[0145] In some exemplary embodiments, the liquid cooling tube is either a corrugated tube or a spiral tube or a combination of the two; or one section of the liquid cooling tube is a straight tube, and the other section is either a corrugated tube or a spiral tube or a combination of the two.

[0146] In some exemplary embodiments, the liquid cooling tube is a liquid outlet tube, and the wire core is located in the liquid outlet tube. The liquid cooling cable also includes a liquid inlet tube, which is arranged side by side with the liquid outlet tube and is connected to the liquid outlet tube via a connector. The liquid cooling tube is made of fluoroplastic.

[0147] In some exemplary embodiments, the cable is applied to a charging gun, and the wire core includes a plurality of positive wire cores and a plurality of negative wire cores electrically connected to the charging gun; the liquid outlet pipe includes a plurality of positive liquid outlet pipes corresponding one-to-one to the plurality of positive wire cores, and a plurality of negative liquid outlet pipes corresponding one-to-one to the plurality of negative wire cores; the liquid inlet pipe includes a plurality of positive liquid inlet pipes corresponding one-to-one to the plurality of positive liquid outlet pipes, and a plurality of negative liquid outlet pipes corresponding one-to-one to the plurality of negative liquid outlet pipes.

[0148] In some exemplary embodiments, the wire core includes: a core material and an insulating layer covering the core material, the liquid outlet pipe is located on a side of the insulating layer away from the core material, and the cooling liquid flows between the insulating layer and the liquid outlet pipe to remove heat generated by the core material.

[0149] In some exemplary embodiments, the liquid cooling pipe is composed of several sections of corrugated pipes, or several sections of spiral pipes.

[0150] In some exemplary embodiments, the liquid cooling tube is a combination of several sections of corrugated tubes and several sections of spiral tubes.

[0151] In some exemplary embodiments, the liquid cooling tube is formed by connecting a section of a straight tube and a section of a corrugated tube; or the liquid cooling tube is formed by connecting a section of a straight tube and a section of a spiral tube.

[0152] In some exemplary embodiments, the liquid cooling tube is formed by connecting several straight tubes and several corrugated tubes; alternatively, the liquid cooling tube is formed by connecting several straight tubes and several spiral tubes; alternatively, the liquid cooling tube is formed by connecting several straight tubes, several corrugated tubes and several spiral tubes.

[0153] In some exemplary embodiments, the present application also provides a charging gun for a new energy vehicle, and the charging gun includes the aforementioned liquid-cooled cable for new energy equipment.

[0154] By setting the liquid outlet pipe to have a corrugated tube or a spiral tube, or a combination of a straight tube and a corrugated tube or a spiral tube, the flexibility of the cable during bending is improved. The stress concentration during bending is reduced, thereby improving the adaptability and durability of the cable. In summary, the core material, the insulating layer and the liquid outlet pipe design in the liquid-cooled cable for new energy equipment are a system that cooperates with each other. By optimizing the structure and materials of each part, efficient heat transfer and dissipation can be achieved, thereby improving the performance and service life of the cable.

[0155] Although the present application has been described with reference to exemplary embodiments, it should be understood that the present application is not limited to the specific embodiments described and illustrated in detail herein. Without departing from the scope defined by the claims of the present application, those skilled in the art can make various changes to the exemplary embodiments.

[0156] The features mentioned and / or illustrated in the above description of the exemplary embodiments of the present application can be combined in the same or similar manner into one or more other embodiments, combined with the features in other embodiments or replace the corresponding features in other embodiments. The technical solutions obtained by such combination or replacement should also be regarded as being included within the protection scope of the present application.

Claims

1. A charging cable, characterized in that: The charging cable (100) comprises: a plurality of power conductors (20), each of the plurality of power conductors (20) extending between a first end (101) of the charging cable (100) and a second end (103) opposite to the first end (101); and a plurality of tubes, each of the plurality of tubes surrounding a corresponding one of the power conductors (20), and forming a cooling medium channel for cooling medium to flow between an outer peripheral surface of the power conductor (20) and an inner peripheral surface of the tube, Each of the plurality of tubes includes an offset portion, wherein a distance (d) between an inner peripheral surface of the offset portion and a central axis (AA) of a corresponding power conductor (20) in a radial direction of the tube varies along a length direction of the tube in a longitudinal cross-sectional view of the tube.

2. The charging cable according to claim 1, characterized in that: The offset portion includes at least one of a helical portion (14) and a corrugated portion (13).

3. The charging cable according to claim 2, characterized in that: The corrugated portion (13) includes a plurality of corrugated convex portions (130) arranged to be spaced apart from each other, and each of the corrugated convex portions (130) extends along the circumferential direction of the tube.

4. The charging cable according to claim 3, characterized in that: In a longitudinal cross-sectional view of the tube, each of the corrugated convex portions (130) is in a V-shape, a U-shape or a trapezoidal shape.

5. The charging cable according to claim 2, characterized in that: The helical portion (14) includes a helical convex portion (140) extending in a helical manner around the central axis of the tube.

6. The charging cable according to claim 2, characterized in that: The offset portion includes a plurality of corrugated portions (13) and / or a plurality of spiral portions (14).

7. The charging cable according to any one of claims 1 to 6, characterized in that: The length of the offset portion is 1% to 100% of the length of the tube.

8. The charging cable according to any one of claims 1 to 6, characterized in that: The minimum bending radius of the offset portion is within a range of 4 to 10 times the outer diameter of the tube, and the minimum bending radius of the charging cable (100) is within a range of 4 to 10 times the outer diameter of the charging cable (100).

9. The charging cable according to any one of claims 1 to 6, characterized in that: The tube is formed as a liquid outlet tube (10), The charging cable (100) further comprises a plurality of liquid inlet pipes (30), wherein the liquid inlet pipes (30) are parallel to and fluidically connected to the liquid outlet pipe (10), and the cooling medium flows into the liquid inlet pipes (30) and flows out through the liquid outlet pipes (10).

10. The charging cable according to claim 9, characterized in that: The plurality of power conductors (20) include a positive power conductor (20A) and a negative power conductor (20B), The liquid inlet pipe (30) comprises a positive electrode liquid inlet pipe (31) and a negative electrode liquid inlet pipe (32); the liquid outlet pipe (10) comprises a positive electrode liquid outlet pipe (11) parallel to and in fluid communication with the positive electrode liquid inlet pipe (31), and a negative electrode liquid outlet pipe (12) parallel to and in fluid communication with the negative electrode liquid inlet pipe (32), The positive electrode power conducting component (20A) is arranged in the positive electrode liquid outlet pipe (11), and the negative electrode power conducting component (20B) is arranged in the negative electrode liquid outlet pipe (12).

11. The charging cable according to claim 9, characterized in that: The plurality of power conductors (20) include two positive power conductors (20A) and two negative power conductors (20B), The liquid inlet pipe (30) comprises a positive electrode liquid inlet pipe (31) and a negative electrode liquid inlet pipe (32); the liquid outlet pipe (10) comprises two positive electrode liquid outlet pipes (11) parallel to and in fluid communication with the positive electrode liquid inlet pipe (31) and two negative electrode liquid outlet pipes (12) parallel to and in fluid communication with the negative electrode liquid inlet pipe (32), The two positive electrode power conducting members (20A) are respectively arranged in the two positive electrode liquid outlet pipes (11), and the two negative electrode power conducting members (20B) are respectively arranged in the two negative electrode liquid outlet pipes (12).

12. The charging cable according to any one of claims 1 to 6, characterized in that: When a direct current of 500A to 800A is applied to the power conductor (20), the temperature of the power conductor (20) of the charging cable is within a range of 50 degrees to 85 degrees.

13. The charging cable according to any one of claims 1 to 6, characterized in that: The nominal cross-sectional area of ​​the core of each of the plurality of power conductors (20) is 16 mm 2 Up to 240mm 2 within the range.

14. The charging cable according to any one of claims 1 to 6, characterized in that: The charging cable also includes a ground wire (60), the nominal cross-sectional area of ​​the core of the ground wire (60) is 2 mm 2 Up to 100mm 2 within the range.

15. The charging cable according to any one of claims 1 to 6, characterized in that: The charging cable further comprises a plurality of signal wires (50), wherein the nominal cross-sectional area of ​​the core of each signal wire (50) is within 0.2 mm 2 Up to 2.5mm 2 within the range.

16. The charging cable according to any one of claims 1 to 6, characterized in that: The tube is made of fluoroplastic.

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