Tensile and torsion-resistant liquid cooling cable for charging of electric vehicle

Abstract

The utility model discloses a tensile and torsion-resistant liquid-cooled cable for charging an electric automobile. The tensile and torsion-resistant liquid-cooled cable comprises a cable core which is mainly composed of a power line core, a signal line core and a cooling pipe. An aramid yarn wrapping layer, an inner sheath layer, an anti-torsion braid layer and an outer sheath layer are sequentially wrapped outside the cable core from inside to outside. According to the utility model, the liquid-cooled cable for charging the electric automobile, which is integrally tensile, torsion-resistant and good in bendability, can reliably bear mechanical strengths such as frequent torsion and stretching, effectively meets the service condition environment, and is good in long-term effect.

Description

Technical Field

[0001] The utility model relates to a cable, in particular to a tensile and torsion-resistant liquid-cooled cable for electric vehicle charging. Background Art

[0002] In order to meet the fast charging technical requirements of electric vehicles, the charging cable used for electric vehicle charging has a large current-carrying power and will generate a large amount of heat. To avoid overheating of the charging cable and improve the safety performance during use, a cooling pipe capable of introducing a cooling medium is usually arranged in the cable core of the charging cable. That is, the cable core of the cable for electric vehicle charging is usually composed of a power line core, a signal line core, a cooling pipe, etc., which is different from conventional power cables. For example, the Chinese patent document with the name of "Flexible High-temperature Self-cooling Charging Cable", publication number CN 219393020 U, publication date July 21, 2023, the name of "A High-power Cable for Electric Vehicle Charging", publication number CN219123017 U, publication date June 2, 2023, and the name of "A Liquid-cooled Charging Cable for Automobile with Tube Liquid-cooling Cooling and Spiral Conductor Structure", publication number CN 116153577 A, publication date May 23, 2023, etc.

[0003] Regarding the structures of various cables for electric vehicle charging currently mastered by the applicant, their formed structures focus on the cooling heat transfer and electromagnetic shielding performance inside the cable core, and do not consider the overall tensile and torsion-resistant performance of the cable structure. However, the cables used for electric vehicle charging need to be frequently stretched, twisted before charging, and twisted and bent after charging during daily use, that is, they need to frequently withstand mechanical stresses such as torsion and tension. It can be seen that the existing charging cables have low tensile and torsion-resistant performance, cannot reliably withstand frequent mechanical strengths such as torsion and tension, and are prone to damage to the line core and / or cooling pipe inside the cable core, and the service durability is poor. Summary of the Utility Model

[0004] The technical object of the utility model is: aiming at the particularity of the service conditions of the cable for electric vehicle charging and the deficiencies of the existing technology, to provide a tensile and torsion-resistant liquid-cooled cable for electric vehicle charging.

[0005] The technical object of the utility model is achieved by the following technical solutions. A tensile and torsion-resistant liquid-cooled cable for electric vehicle charging includes a cable core mainly composed of a power line core, a signal line core, and a cooling pipe.

[0006] The outside of the cable core is sequentially coated with an aramid yarn wrapping layer, an inner sheath layer, a torsion-resistant braided layer, and an outer sheath layer from inside to outside.

[0007] In view of the particularity of the service conditions of the cable for electric vehicle charging, the protective structure outside the cable core is formed by combining an aramid yarn wrapping layer and a braided layer with tensile, torsional resistance and flexible bending properties, together with inner and outer sheath layers, so as to obtain a liquid-cooled cable for electric vehicle charging with good overall tensile, torsional and bending properties, which can reliably withstand mechanical stresses such as frequent torsion and tension, effectively meet the service condition environment, and has good long-term performance.

[0008] As one of the preferred solutions, a plurality of liquid leakage sensors are arranged at intervals along the longitudinal length of the cooling pipe on the outer wall of the cooling pipe in the cable core, and these liquid leakage sensors are connected in series in sequence;

[0009] The interval distance between adjacent liquid leakage sensors is 0.8 - 1.5 m.

[0010] In view of the working particularity of the liquid-cooled cable, the service state of the cooling pipe is dynamically monitored by the liquid leakage sensors, so as to timely detect the phenomenon of liquid leakage caused by damage to the cooling pipe, and minimize the safety risk as much as possible, with good safety performance.

[0011] As one of the preferred solutions, the cable core has two power cores, four signal cores and two cooling pipes;

[0012] The two power cores are arranged side by side, the two cooling pipes are dispersedly arranged in the corresponding gaps on both sides of the two power cores, the four signal cores are dispersedly arranged in each corresponding gap between the cooling pipes and the power cores, and the cooling pipes are in contact and cooperation with the two power cores and the two signal cores on the same side respectively.

[0013] Under the premise of meeting the use functions, the cable core of the above technical measures has a compact formed structure and good roundness.

[0014] Furthermore, a mesh structure filling rope made of PP material is filled in the gaps in the cable core. This technical measure is beneficial to the roundness of the cable core and also beneficial to improving the tensile and torsional resistance of the cable core, so as to cooperate with the external protective structure to obtain a liquid-cooled cable for electric vehicle charging with good overall tensile, torsional and bending properties.

[0015] Furthermore, the power core is composed of a power conductor and a power insulation layer coated on the outside of the power conductor;

[0016] The power conductor is composed of several soft copper conductors with a single wire diameter of 0.1 - 0.3 mm, and is formed in a multi-layer co-directional stranded structure;

[0017] The power insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of 1.4 - 1.8 mm and a temperature resistance of 125 °C.

[0018] The power cord core of the above technical measure has excellent soft bending performance on the premise of meeting the use function.

[0019] Further, the signal wire core is composed of two signal single wires in a twisted pair, an aluminum-plastic composite tape layer covering the twisted signal single wires, and a tinned copper wire braided layer, and the tinned copper wire braided layer is outside the aluminum-plastic composite tape layer;

[0020] The aluminum side of the aluminum-plastic composite tape layer faces outward;

[0021] The tinned copper wire braided layer is a braided structure of tinned copper wires with a single wire diameter of 0.10 - 0.15 mm.

[0022] Still further, the signal single wire of the signal wire core is composed of a signal conductor and a signal insulation layer covering the outside of the signal conductor;

[0023] The signal conductor is composed of several soft copper conductors with a single wire diameter of 0.1 - 0.3 mm twisted together;

[0024] The signal insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of 0.4 - 0.6 mm and a temperature resistance of 125 °C.

[0025] The signal wire core of the above technical measure has excellent electromagnetic shielding and soft bending performance on the premise of meeting the use function, and the signal transmission is stable.

[0026] As one of the preferred solutions, the inner sheath layer is an extrusion structure of a cross-linked polyolefin material with a thickness of 0.5 - 0.7 mm and a temperature resistance of 125 °C.

[0027] As one of the preferred solutions, the anti-twist braided layer is a braided structure of tinned copper wires with a single wire diameter of 0.2 - 0.3 mm.

[0028] As one of the preferred solutions, the outer sheath layer is an extrusion structure of a thermoplastic elastomer material.

[0029] The beneficial technical effects of the present utility model are: aiming at the particularity of the service condition environment of the above-mentioned electric vehicle charging cable, the above technical measures can obtain an electric vehicle charging liquid-cooled cable with good overall tensile, anti-twist and bending properties, which can reliably withstand mechanical strengths such as frequent torsion and tension. At the same time, it can dynamically monitor the liquid leakage state during the service of the cooling pipe, minimize the safety risk as much as possible, effectively meet the service condition environment, and has good long-term performance and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of the present utility model.

[0031] Meanings of the codes in the figure: 1—power supply core; 11—power supply conductor; 12—power supply insulation layer; 2—signal line core; 21—signal conductor; 22—signal insulation layer; 23—aluminum-plastic composite tape layer; 24—tinned copper wire braided layer; 3—cooling pipe; 4—liquid leakage sensor; 5—filling rope; 6—aramid yarn wrapping layer; 7—inner sheath layer; 8—anti-twist braided layer; 9—outer sheath layer. Specific embodiments

[0032] The present utility model relates to a cable, specifically a tensile and anti-twist liquid-cooled cable for electric vehicle charging. The main technical solution of the present utility model will be specifically described below in combination with multiple embodiments. Among them, Embodiment 1 is combined with the accompanying drawings of the specification, that is Figure 1 The technical solution content of the present utility model is clearly and detailedly explained; although the other embodiments are not separately drawn with drawings, their main structures can still refer to the drawings of Embodiment 1.

[0033] It should be particularly noted here that the drawings of the present utility model are schematic. In order to clarify the technical purpose of the present utility model, unnecessary details have been simplified to avoid obscuring the technical solution contributed by the present utility model to the prior art. In addition, the expressions such as "about" and "substantially" regarding the quantity or mating relationship in the following text mean that reasonable assembly errors, processing errors, etc. are allowed in the industry, rather than literally expressing the absolute quantity or mating relationship.

[0034] Embodiment 1

[0035] See Figure 1 As shown, the present utility model is a tensile and anti-twist liquid-cooled cable for electric vehicle charging, which includes a cable core and an aramid yarn wrapping layer 6, an inner sheath layer 7, an anti-twist braided layer 8 and an outer sheath layer 9 sequentially coated on the outside of the cable core from inside to outside.

[0036] Specifically, the cable core has two power supply cores 1, four signal line cores 2, two cooling pipes 3 and multiple filling ropes 5. Among the two power supply cores 1, one is the positive power supply core and the other is the negative power supply core. Among the two cooling pipes 3, one is for the coolant to flow in and the other is for the coolant to flow out.

[0037] Among them, each power supply core 1 is composed of a power supply conductor 11 and a power supply insulation layer 12 coated on the outside of the power supply conductor 11. The power supply conductor 11 is composed of several soft copper conductors with a single wire diameter of about 0.2 mm, and is formed by a three-layer co-directional composite stranding structure arranged in concentric circles. The power supply insulation layer 12 is an extrusion structure of a cross-linked polyolefin material with a thickness of about 1.6 mm and a temperature resistance of 125 °C.

[0038] Each signal wire core 2 is composed of two twisted signal single wires, an aluminum-plastic composite tape layer 23 covering the twisted signal single wires, and a tinned copper wire braided layer 24. Each signal single wire is composed of a signal conductor 21 and a signal insulation layer 22 covering the outside of the signal conductor 21; the signal conductor 21 is formed by stranding several soft copper conductors with a single wire diameter of about 0.2 mm; the signal insulation layer 22 is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.5 mm and a temperature resistance of 125 °C. The two signal single wires are twisted together with a pitch ratio of about 15 times. The tinned copper wire braided layer 24 is located outside the aluminum-plastic composite tape layer 23. The aluminum-plastic composite tape layer 23 is an overlapping winding structure of an aluminum-plastic composite tape with an overlapping rate of about 30%, and the aluminum side of the aluminum-plastic composite tape faces outward. The tinned copper wire braided layer 24 is a braided structure of tinned copper wires with a single wire diameter of about 0.12 mm and a braiding density of about 90%.

[0039] Each cooling pipe 3 is formed by compound molding of excellent-performance PP material and PA material, and its internal channel is used for the flow and heat exchange of an ethylene glycol water-based liquid. To timely detect the damage state and liquid leakage state of the cooling pipe 3, a plurality of liquid leakage sensors 4 are arranged at intervals along the longitudinal length direction of each cooling pipe 3 on the outer wall of each cooling pipe 3. The interval distance between adjacent liquid leakage sensors 4 is about 1 m, and these liquid leakage sensors 4 are connected in series in turn. Each liquid leakage sensor 4 uses a high-sensitivity microchip.

[0040] Each filling rope 5 is a net-like structure formed by PP material (i.e., polypropylene material).

[0041] The components constituting the cable core are arranged according to the following basic structural rules:

[0042] Two power wire cores 1 are arranged closely side by side;

[0043] Two cooling pipes 3 are dispersedly arranged at the corresponding gaps on both sides of the two power wire cores 1, and each cooling pipe 3 forms a contact fit with the two power wire cores 1 on the corresponding side. The two cooling pipes 3 are basically symmetrically arranged along the two power wire cores 1. Similarly, the two power wire cores 1 are basically symmetrically arranged along the two cooling pipes 3 to form sufficient heat exchange during use;

[0044] Four signal wire cores 2 are dispersedly arranged at the corresponding gaps between each cooling pipe 3 and each power wire core 1. The cooling pipe 3 forms a contact fit with the two signal wire cores 2 on the same side respectively, that is, the cooling pipe 3 forms a contact fit with the two power wire cores 1 and the two signal wire cores 2 on the same side respectively;

[0045] Multiple filling ropes 5 are filled in the gaps formed by the two power wire cores 1, the two cooling pipes 3, and the four signal wire cores 2 and are made into a complete circle.

[0046] The aramid yarn wrapping layer 6 is a two-layer overlapping wrapping structure of aramid yarns, and the overlapping wrapping rate of each layer is about 30%.

[0047] The inner sheath layer 7 is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.6 mm and a temperature resistance of 125 °C.

[0048] The anti-torsion braided layer 8 is a braided structure of tinned copper wires with a single wire diameter of about 0.2 mm, and the braiding density is about 90%.

[0049] The outer sheath layer 9 is an extrusion structure of a thermoplastic elastomer material.

[0050] Embodiment 2

[0051] The utility model relates to a tensile and anti-torsion liquid-cooled cable for electric vehicle charging, which comprises a cable core and an aramid yarn wrapping layer, an inner sheath layer, an anti-torsion braided layer and an outer sheath layer which are sequentially coated on the outside of the cable core from inside to outside.

[0052] Specifically, the cable core has two power cores, four signal cores, two cooling pipes and multiple filling ropes. Among the two power cores, one is a positive power core and the other is a negative power core. Among the two cooling pipes, one is for the coolant to flow in and the other is for the coolant to flow out.

[0053] Wherein, each power core is composed of a power conductor and a power insulation layer coated on the outside of the power conductor. The power conductor is composed of several soft copper conductors with a single wire diameter of about 0.3 mm, and is composed of a three-layer co-directional composite stranding structure arranged in concentric circles. The power insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 1.4 mm and a temperature resistance of 125 °C.

[0054] Each signal core is composed of two twisted signal single wires, an aluminum-plastic composite tape layer coated on the twisted signal single wires and a tinned copper wire braided layer. Each signal single wire is composed of a signal conductor and a signal insulation layer coated on the outside of the signal conductor; the signal conductor is composed of several soft copper conductors with a single wire diameter of about 0.3 mm twisted together; the signal insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.6 mm and a temperature resistance of 125 °C. The two signal single wires are twisted together with a lay ratio of about 13 times. The tinned copper wire braided layer is located outside the aluminum-plastic composite tape layer. The aluminum-plastic composite tape layer is an overlapping wrapping structure of an aluminum-plastic composite tape, and the overlapping rate is about 25%, and the aluminum side of the aluminum-plastic composite tape faces outward. The tinned copper wire braided layer is a braided structure of tinned copper wires with a single wire diameter of about 0.15 mm, and the braiding density is about 85%.

[0055] Each cooling pipe is formed by compound molding of excellent-performance PP material and PA material, and its internal channel is used for the flow and heat exchange of ethylene glycol water-based liquid. To timely detect the damage state and liquid leakage state of the cooling pipe, at the outer wall of each cooling pipe, a plurality of liquid leakage sensors are arranged at intervals along the longitudinal direction of the cooling pipe, and the interval distance between adjacent liquid leakage sensors is about 0.8 m. These liquid leakage sensors are successively connected in series. Each liquid leakage sensor uses a high-sensitivity microchip.

[0056] Each filling rope is a net-like structure formed by PP material (i.e., polypropylene material).

[0057] The components constituting the cable core are arranged according to the following basic structural rules:

[0058] Two power cores are arranged closely side by side;

[0059] Two cooling pipes are dispersedly arranged at the corresponding gaps on both sides of the two power cores, and each cooling pipe forms a contact fit with the two power cores on the corresponding side. The two cooling pipes are basically arranged symmetrically along the two power cores. Similarly, the two power cores are basically arranged symmetrically along the two cooling pipes to form sufficient heat exchange during use;

[0060] Four signal cores are dispersedly arranged at the corresponding gaps between each cooling pipe and each power core. The cooling pipe forms a contact fit with the two signal cores on the same side respectively, that is, the cooling pipe forms a contact fit with the two power cores and the two signal cores on the same side respectively;

[0061] Multiple filling ropes are filled in the gaps formed by the two power cores, two cooling pipes, and four signal cores described above and made into a complete circle.

[0062] The aramid yarn wrapping layer is a three-layer overlapping wrapping structure of aramid yarn, and the overlapping wrapping rate of each layer is about 25%.

[0063] The inner sheath layer is an extrusion structure of cross-linked polyolefin material with a thickness of about 0.7 mm and a temperature resistance of 125 °C.

[0064] The anti-torsion braided layer is a braided structure of tinned copper wire with a single wire diameter of about 0.3 mm, and the braiding density is about 88%.

[0065] The outer sheath layer is an extrusion structure of thermoplastic elastomer material.

[0066] Embodiment 3

[0067] The utility model relates to a tensile and torsion-resistant liquid-cooled cable for electric vehicle charging, which comprises a cable core and an aramid yarn wrapping layer, an inner sheath layer, an anti-torsion braided layer, and an outer sheath layer successively coated on the outside of the cable core from inside to outside.

[0068] Specifically, the cable core has two power cores, four signal cores, two cooling tubes and multiple filling ropes. Among the two power cores, one is the positive power core and the other is the negative power core. Among the two cooling tubes, one is for the coolant to flow in and the other is for the coolant to flow out.

[0069] Among them, each power core is composed of a power conductor and a power insulation layer coated on the outside of the power conductor. The power conductor is composed of several soft copper conductors with a single wire diameter of about 0.1 mm, and is composed of a five-layer coaxial right-stranded structure arranged concentrically. The power insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 1.8 mm and a temperature resistance of 125 °C.

[0070] Each signal core is composed of two twisted signal single wires, an aluminum-plastic composite tape layer coated on the twisted signal single wires and a tinned copper wire braided layer. Each signal single wire is composed of a signal conductor and a signal insulation layer coated on the outside of the signal conductor; the signal conductor is composed of several soft copper conductors with a single wire diameter of about 0.1 mm twisted together; the signal insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.4 mm and a temperature resistance of 125 °C. The two signal single wires are twisted together with a lay ratio of about 12 times. The tinned copper wire braided layer is located outside the aluminum-plastic composite tape layer. The aluminum-plastic composite tape layer is an overlapping winding structure of an aluminum-plastic composite tape, and the overlapping rate is about 35%. The aluminum side of the aluminum-plastic composite tape faces outward. The tinned copper wire braided layer is a braided structure of tinned copper wires with a single wire diameter of about 0.10 mm, and the braiding density is about 95%.

[0071] Each cooling tube is formed by compound molding of excellent performance PP material and PA material, and its internal channel is used for the flow and heat exchange of ethylene glycol water-based liquid. To timely detect the damage state and liquid leakage state of the cooling tube, at the outer wall of each cooling tube, a plurality of liquid leakage sensors are arranged at intervals along the longitudinal length of the cooling tube. The interval distance between adjacent liquid leakage sensors is about 1.5 m, and these liquid leakage sensors are connected in series in turn. Each liquid leakage sensor uses a high-sensitivity microchip.

[0072] Each filling rope is a mesh structure formed by PP material (i.e., polypropylene material).

[0073] The components constituting the cable core are arranged according to the following basic structural rules:

[0074] The two power cores are arranged adjacent to each other side by side;

[0075] The two cooling tubes are dispersed and arranged in the corresponding gaps on both sides of the two power cores, and each cooling tube forms a contact fit with the two power cores on the corresponding side. The two cooling tubes are basically arranged symmetrically along the two power cores. Similarly, the two power cores are basically arranged symmetrically along the two cooling tubes to form sufficient heat exchange during use;

[0076] Four signal wire cores are dispersedly arranged at the corresponding gaps between each cooling pipe and each power wire core. Each cooling pipe is in contact and cooperation with two signal wire cores on the same side, that is, each cooling pipe is in contact and cooperation with two power wire cores and two signal wire cores on the same side respectively.

[0077] Multiple filling ropes are filled in the gaps formed by the aforementioned two power wire cores, two cooling pipes, and four signal wire cores and are made into a complete circle.

[0078] The aramid yarn wrapping layer is a two-layer overlapping wrapping structure of aramid yarn, and the overlapping wrapping rate of each layer is about 35%.

[0079] The inner sheath layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.5 mm and a temperature resistance of 125 °C.

[0080] The anti-twist braided layer is a braided structure of tinned copper wires with a single wire diameter of about 0.25 mm, and the braiding density is about 92%.

[0081] The outer sheath layer is an extrusion structure of a thermoplastic elastomer material.

[0082] Embodiment 4

[0083] The utility model relates to a tensile and anti-twist liquid-cooled cable for electric vehicle charging, which comprises a cable core and an aramid yarn wrapping layer, an inner sheath layer, an anti-twist braided layer, and an outer sheath layer that are sequentially coated on the outside of the cable core from the inside to the outside.

[0084] Specifically, the cable core has two power wire cores, two signal wire cores, two cooling pipes, and multiple filling ropes. Among the two power wire cores, one is a positive power wire core and the other is a negative power wire core. Among the two cooling pipes, one is for the coolant to flow in and the other is for the coolant to flow out.

[0085] Wherein, each power wire core is composed of a power conductor and a power insulation layer coated on the outside of the power conductor. The power conductor is composed of several soft copper conductors with a single wire diameter of about 0.15 mm and is in a three-layer co-directional composite stranding structure arranged in concentric circles. The power insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 1.5 mm and a temperature resistance of 125 °C.

[0086] Each signal wire core is composed of two signal single wires twisted together, an aluminum-plastic composite tape layer covering the twisted signal single wires, and a tinned copper wire braided layer. Each signal single wire is composed of a signal conductor and a signal insulation layer covering the outside of the signal conductor; the signal conductor is formed by stranding several soft copper conductors with a single wire diameter of about 0.2 mm; the signal insulation layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.5 mm and a temperature resistance of 125 °C. The two signal single wires are twisted together with a lay ratio of about 18 times. The tinned copper wire braided layer is located outside the aluminum-plastic composite tape layer. The aluminum-plastic composite tape layer is an overlapping winding structure of an aluminum-plastic composite tape, with an overlap rate of about 20%, and the aluminum side of the aluminum-plastic composite tape faces outward. The tinned copper wire braided layer is a braided structure of tinned copper wires with a single wire diameter of about 0.13 mm, and the braiding density is about 95%.

[0087] Each cooling tube is formed by compound molding of excellent-performance PP material and PA material, and its internal channel is used for the flow and heat exchange of ethylene glycol water-based liquid. To timely detect the damage state and liquid leakage state of the cooling tube, at the outer wall of each cooling tube, a plurality of liquid leakage sensors are arranged at intervals along the longitudinal length of the cooling tube, and the interval distance between adjacent liquid leakage sensors is about 1.2 m, and these liquid leakage sensors are connected in series in turn. Each liquid leakage sensor uses a high-sensitivity microchip.

[0088] Each filling cord is a mesh structure formed by PP material (i.e., polypropylene material).

[0089] The components constituting the cable core are arranged according to the following basic structural rules:

[0090] Two power wire cores are arranged closely side by side;

[0091] Two cooling tubes are dispersedly arranged at the corresponding gaps on both sides of the two power wire cores, and each cooling tube forms a contact fit with the two power wire cores on the corresponding side. The two cooling tubes are basically symmetrically arranged along the two power wire cores. Similarly, the two power wire cores are basically symmetrically arranged along the two cooling tubes to form sufficient heat exchange during use;

[0092] Two signal wire cores are dispersedly arranged at the corresponding gaps between each cooling tube and any one power wire core. The cooling tube is in contact fit with the signal wire core, that is, the cooling tube is in contact fit with the two power wire cores and the corresponding signal wire core respectively;

[0093] Multiple filling cords are filled in the gaps formed by the two power wire cores, two cooling tubes, and two signal wire cores and are made into a round shape.

[0094] The aramid yarn wrapping layer is a three-layer overlapping wrapping structure of aramid yarn, and the overlapping wrapping rate of each layer is about 40%.

[0095] The inner sheath layer is an extrusion structure of cross-linked polyolefin material with a thickness of about 0.6 mm and a temperature resistance of 125 °C.

[0096] The anti-twist braided layer is a braided structure of tinned copper wire with a single wire diameter of about 0.2 mm, and the braiding density is about 95%.

[0097] The outer sheath layer is an extrusion structure of thermoplastic elastomer material.

[0098] Example 5

[0099] The utility model is a tensile and anti-twist liquid-cooled cable for electric vehicle charging, which includes a cable core and an aramid yarn wrapping layer, an inner sheath layer, an anti-twist braided layer, and an outer sheath layer that are sequentially coated on the outside of the cable core from the inside to the outside.

[0100] Specifically, the cable core has two power cores, four signal cores, two cooling pipes, and multiple filling ropes. Among the two power cores, one is the positive power core and the other is the negative power core. Among the two cooling pipes, one is for the coolant to flow in and the other is for the coolant to flow out.

[0101] Among them, each power core is composed of a power conductor and a power insulation layer coated on the outside of the power conductor. The power conductor is composed of several soft copper conductors with a single wire diameter of about 0.3 mm, and is composed of a three-layer co-directional composite stranded structure arranged in concentric circles. The power insulation layer is an extrusion structure of cross-linked polyolefin material with a thickness of about 1.7 mm and a temperature resistance of 125 °C.

[0102] Each signal core is composed of two twisted signal single wires, an aluminum-plastic composite tape layer coated on the twisted signal single wires, and a tinned copper wire braided layer. Each signal single wire is composed of a signal conductor and a signal insulation layer coated on the outside of the signal conductor; the signal conductor is composed of several soft copper conductors with a single wire diameter of about 0.1 mm twisted together; the signal insulation layer is an extrusion structure of cross-linked polyolefin material with a thickness of about 0.6 mm and a temperature resistance of 125 °C. The two signal single wires are twisted together with a pitch ratio of about 16 times. The tinned copper wire braided layer is on the outside of the aluminum-plastic composite tape layer. The aluminum-plastic composite tape layer is an overlapping wrapping structure of aluminum-plastic composite tape, and the overlapping rate is about 30%. The aluminum side of the aluminum-plastic composite tape faces outward. The tinned copper wire braided layer is a braided structure of tinned copper wire with a single wire diameter of about 0.14 mm, and the braiding density is about 92%.

[0103] Each cooling pipe is formed by compounding excellent-performance PP material and PA material, and its internal channel is used for the flow and heat exchange of ethylene glycol water-based liquid. To timely detect the damage state and liquid leakage state of the cooling pipe, multiple liquid leakage sensors are arranged at intervals along the longitudinal length of the cooling pipe on the outer wall of each cooling pipe. The interval distance between adjacent liquid leakage sensors is about 1 m, and these liquid leakage sensors are sequentially connected in series. Each liquid leakage sensor uses a high-sensitivity microchip.

[0104] Each filling rope is a net-like structure formed of PP material (i.e., polypropylene material).

[0105] The components constituting the cable core are arranged according to the following basic structural rules:

[0106] Two power cores are arranged closely side by side;

[0107] Two cooling pipes are dispersedly arranged at the corresponding gaps on both sides of the two power cores, and each cooling pipe forms a contact fit with the two power cores on the corresponding side. The two cooling pipes are basically symmetrically arranged along the two power cores. Similarly, the two power cores are basically symmetrically arranged along the two cooling pipes to form sufficient heat exchange during use;

[0108] Four signal cores are dispersedly arranged at the corresponding gaps between each cooling pipe and each power core. The cooling pipe is in contact fit with the two signal cores on the same side respectively, that is, the cooling pipe is in contact fit with the two power cores and the two signal cores on the same side respectively;

[0109] Multiple filling ropes are filled in the gaps formed by the two power cores, two cooling pipes, and four signal cores described above and are made into a complete circle.

[0110] The aramid yarn wrapping layer is a two-layer overlapping wrapping structure of aramid yarn, and the overlapping wrapping rate of each layer is about 35%.

[0111] The inner sheath layer is an extrusion structure of a cross-linked polyolefin material with a thickness of about 0.7 mm and a temperature resistance of 125 °C.

[0112] The anti-torsion braided layer is a braided structure of tinned copper wires with a single wire diameter of about 0.2 mm, and the braiding density is about 93%.

[0113] The outer sheath layer is an extrusion structure of a thermoplastic elastomer material.

[0114] The above embodiments are only used to illustrate the present invention, rather than to limit it.

[0115] Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that they can still modify the specific technical solutions in the above embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the present invention.

Claims

1. A tensile and torsion-resistant liquid-cooled cable for charging an electric vehicle, comprising a cable core mainly composed of a power line core (1), a signal line core (2) and a cooling tube (3); Features: The outside of the cable core is coated with an aramid yarn wrapping layer (6), an inner sheath layer (7), an anti-twist braided layer (8) and an outer sheath layer (9) in sequence from the inside to the outside; On the outer wall of the cooling tube (3) in the cable core, a plurality of liquid leakage sensors (4) are arranged at intervals along the longitudinal direction of the cooling tube (3), and the liquid leakage sensors (4) are connected in series in sequence; The spacing between adjacent liquid leakage sensors (4) is 0.8 to 1.5 m.

2. According to claim 1, the tensile and torsion-resistant liquid-cooled cable for charging electric vehicles is characterized in that: The cable core comprises two power line cores (1), four signal line cores (2) and two cooling tubes (3); Two power line cores (1) are arranged side by side, two cooling tubes (3) are dispersedly arranged at corresponding gaps on both sides of the two power line cores (1), four signal line cores (2) are dispersedly arranged at each corresponding gap between the cooling tubes (3) and the power line cores (1), and the cooling tubes (3) are in contact and fit with the two power line cores (1) and the two signal line cores (2) on the same side, respectively.

3. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 2, characterized in that: The gaps in the cable core are filled with a mesh-structured filling rope (5) made of PP material.

4. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 2, characterized in that: The power line core (1) is composed of a power conductor (11) and a power insulation layer (12) covering the outside of the power conductor (11); The power conductor (11) is a plurality of soft copper conductors with a single wire diameter of 0.1 to 0.3 mm, which are formed in a multi-layer co-directional twisted structure; The power supply insulation layer (12) is an extruded structure of a cross-linked polyolefin material having a thickness of 1.4 to 1.8 mm and a temperature resistance of 125°C.

5. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 2, characterized in that: The signal wire core (2) is composed of two twisted signal single wires, and an aluminum-plastic composite tape layer (23) and a tinned copper wire braided layer (24) covering the twisted signal single wires, wherein the tinned copper wire braided layer (24) is located outside the aluminum-plastic composite tape layer (23); The aluminum surface of the aluminum-plastic composite tape layer (23) faces outwards; The tinned copper wire braided layer (24) is a tinned copper wire braided structure with a single wire diameter of 0.10 to 0.15 mm.

6. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 5, characterized in that: The signal single wire of the signal wire core (2) is composed of a signal conductor (21) and a signal insulation layer (22) covering the outside of the signal conductor (21); The signal conductor (21) is formed by twisting together a plurality of soft copper conductors with a single wire diameter of 0.1 to 0.3 mm; The signal insulation layer (22) is an extruded structure of a cross-linked polyolefin material having a thickness of 0.4 to 0.6 mm and a temperature resistance of 125°C.

7. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 1, characterized in that: The inner sheath layer (7) is an extruded structure of a cross-linked polyolefin material having a thickness of 0.5 to 0.7 mm and being resistant to 125°C.

8. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 1, characterized in that: The anti-twist braided layer (8) is a tinned copper wire braided structure with a single wire diameter of 0.2 to 0.3 mm.

9. The tensile and torsion-resistant liquid-cooled cable for charging electric vehicles according to claim 1, characterized in that: The outer sheath layer (9) is an extruded structure of a thermoplastic elastomer material.

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