Liquid-cooled wire assembly and liquid-cooled charging socket

Abstract

The utility model discloses a liquid-cooled lead assembly and a liquid-cooled charging socket, the liquid-cooled lead assembly is composed of a hollow conductive tube, a flexible liquid conduit and an insulating layer coated outside the hollow conductive tube and the flexible liquid conduit, two end portions of the hollow conductive tube are flattened and formed, a transition area is formed close to the flattened and formed position, and the hollow conductive tube is provided with a plurality of through holes. A strip-shaped via hole is punched and formed in the transition area in the length direction of the transition area; the flexible liquid conduit is arranged in the hollow conductive tube, and two ends of the flexible liquid conduit respectively penetrate through the via holes in two ends of the hollow conductive tube; the hollow conductive tube and the flexible liquid conduit at the same end are respectively connected with a power jack of the liquid cooling charging socket and the water cooling box body, and cooling liquid is transmitted into the flexible liquid conduit through the water cooling box body and circulates in the flexible liquid conduit so as to cool the hollow conductive tube. According to the liquid-cooled charging socket, the flexible liquid conduit communicated with the water-cooled box body is arranged in the hollow conductive tube of the liquid-cooled wire assembly, so that the cooling liquid circulates through the flexible liquid conduit, and the hollow conductive tube, the liquid-cooled wire assembly and the whole liquid-cooled charging socket are effectively cooled; and during high-power charging, heating on a charging link is controlled, so that the charging time is shortened, and the charging experience of a user is improved.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle charging socket technology, specifically, a liquid-cooled wire assembly and a liquid-cooled charging socket. Background Technology

[0002] With the increasing popularity of new energy vehicles, the growing number of electric vehicle users has higher and higher requirements for charging speed. Charging power is increasing, and charging time is getting shorter. With the widespread adoption of liquid-cooled charging technology at the charging gun end, the charging current is also increasing. However, most vehicles still use traditional DC charging sockets. As charging power increases, so does the current. In this charging chain, the charging gun, using liquid cooling technology, can quickly dissipate heat, actively cooling the charging gun and cable; but traditional DC charging sockets rely on natural convection for cooling, a passive natural cooling method. Under high current, the heat generated cannot be dissipated quickly, limiting the increase in charging power and affecting the charging experience. This becomes a bottleneck in the entire charging chain. Sustained high current can even lead to overheating of the charging socket, causing thermal failure, overheating and burning. Utility Model Content

[0003] The purpose of this invention is to provide a liquid-cooled wire assembly and a liquid-cooled charging socket to solve the technical problem of low heat dissipation efficiency caused by the charging cable in a traditional DC charging socket dissipating heat through natural heat convection.

[0004] The present invention solves the above problems through the following technical solution:

[0005] A liquid-cooled lead assembly comprises a hollow conductive tube, a flexible liquid conduit, and an insulating layer covering the hollow conductive tube and the flexible liquid conduit. The two ends of the hollow conductive tube are flattened, and a transition region is formed near the flattening point. A strip-shaped through hole is punched along the length of the transition region. The flexible liquid conduit is disposed inside the hollow conductive tube, and its two ends pass through the through holes at both ends of the hollow conductive tube. The hollow conductive tube and the flexible liquid conduit at the same end are connected to the power socket of the liquid-cooled charging socket and the water-cooled housing, respectively. The coolant is transferred to the flexible liquid conduit through the water-cooled housing and flows in the flexible liquid conduit to dissipate heat from the hollow conductive tube.

[0006] As a further improvement, a transition fillet is formed inside the via.

[0007] As a further improvement, the hollow conductive tube is welded or threaded to the power socket.

[0008] As a further improvement, the hollow conductive tube is a hollow copper tube or a hollow aluminum alloy tube.

[0009] Meanwhile, the present invention solves the above problems through the following technical solution:

[0010] A liquid-cooled charging socket includes: a charging socket flange assembly, a liquid-cooled socket housing, and a liquid-cooled wire assembly as described above. The charging socket flange assembly has a power socket and a water-cooled housing. The power socket is connected to a hollow conductive tube at one end of the liquid-cooled wire assembly. The water-cooled housing is connected to a flexible liquid conduit at the same end of the liquid-cooled wire assembly. The liquid-cooled socket housing covers one end of the charging socket flange assembly connected to the liquid-cooled wire assembly, and the other end of the liquid-cooled wire assembly passes through the liquid-cooled socket housing.

[0011] As a further improvement, the water-cooled housing is also provided with a liquid inlet, which is connected to the cooling pump.

[0012] As a further improvement, a water tank mounting hole is formed inside the charging socket flange assembly. The water tank mounting hole is located between the two power sockets and is used to install the water-cooled housing into the charging socket flange assembly with self-tapping screws.

[0013] As a further improvement, the flexible liquid conduit is interference-fitted to the water nozzle of the water-cooled box and locked with a clamp.

[0014] As a further improvement, thermally conductive silicone grease is applied between the water-cooled housing and the power socket.

[0015] As a further improvement, the charging socket flange assembly is snapped into the liquid-cooled socket housing and secured with self-tapping screws.

[0016] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0017] This invention, within the boundaries specified by traditional national standard DC sockets, utilizes a flexible liquid conduit connected to a water-cooled housing within the hollow conductive tube of the liquid-cooled wire assembly. This allows coolant to circulate through the flexible liquid conduit, effectively dissipating heat from the hollow conductive tube, the liquid-cooled wire assembly, and the entire liquid-cooled charging socket. Furthermore, in conjunction with the increasingly prevalent liquid-cooled charging gun technology, it controls heat generation along the charging path during high-power charging, shortening charging time and improving the user's charging experience. Attached Figure Description

[0018] Figure 1 This is an exploded view of a liquid-cooled charging socket according to the present invention.

[0019] Figure 2 This is a cross-sectional schematic diagram of a liquid-cooled lead wire assembly according to the present invention.

[0020] Reference numerals: 101, charging socket flange assembly; 102, liquid-cooled socket housing; 103, first self-tapping screw; 104, water-cooled housing; 105, liquid-cooled wire assembly; 106, power socket sealing ring; 107, power socket end cap; 108, second self-tapping screw; 109, grounding socket sealing ring; 110, clamp; 111, grounding socket end cap; 1011, water tank mounting hole; 1012, power socket; 1151, hollow conductive tube; 1152, flexible liquid conduit; 1153, insulation layer; 1154, transition area; 1155, through hole. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] Example 1

[0023] Combined with appendix Figure 1-2 As shown, a liquid-cooled conductor assembly 105 comprises a hollow conductive tube 1151, a flexible liquid conduit 1152, and an insulating layer 1153 covering the hollow conductive tube 1151 and the flexible liquid conduit 1152. The hollow conductive tube 1151 is flattened at both ends, with one end of the flattened shape used for ultrasonic welding to a conductive terminal (power socket), or it can be flattened for bolt connection. Transition regions 1154 are formed at both ends of the hollow conductive tube 1151 near the flattened portion. Strip-shaped through holes 1155 are punched along the length of these transition regions 1154. The flexible liquid conduit 1152 is disposed within the hollow conductive tube 1151, with both ends passing through the through holes 1155 at both ends of the hollow conductive tube 1151. Preferably, the through holes 1155 are physically rounded to protect the flexible liquid conduit 1152 from scratches by sharp punching edges during insertion and exit. During operation, the hollow conductive tube 1151 is connected to the power socket 1012 of the liquid-cooled charging socket, and the high-temperature resistant and coolant-resistant flexible liquid conduit 1152 is connected to the water nozzle of the water-cooled housing 104 of the liquid-cooled charging socket, so that the coolant is transferred through the water-cooled housing 104 to the flexible liquid conduit 1152 and flows in the flexible liquid conduit 1152 to exchange heat with the hollow conductive tube 1151, thereby achieving the purpose of heat dissipation and cooling.

[0024] In this embodiment, the liquid-cooled wire assembly 105 can be bent into irregular shapes by the hollow conductive tube 1151 to adapt to different wiring layouts in the vehicle. The flexible liquid conduit 1152 is resistant to coolant corrosion and high temperature; it can deform along with the bending deformation of the hollow conductive tube 1151, making it suitable for various irregular layouts. Meanwhile, except for the two ends which require electro-hydraulic separation, the remaining parts of the flexible liquid conduit 1152 are all arranged inside the hollow conductive tube 1151, reducing the probability of physical damage and improving stability.

[0025] Preferably, the hollow conductive tube is a hollow copper tube or a hollow aluminum alloy tube. A hollow copper tube or aluminum alloy tube with good electrical and thermal conductivity is used, and an insulating layer 1153 is coated onto its exterior through processes such as encapsulation or extrusion. The insulating layer 1153 is made of cross-linked polyolefin or a material with equivalent performance, forming a protective layer with insulating properties.

[0026] Example 2

[0027] See attached document Figure 1 A liquid-cooled charging socket includes: a charging socket flange assembly 101, a liquid-cooled socket housing 102, a water-cooled enclosure 104, and a liquid-cooled wire assembly 105 as described above. One end of the charging socket flange assembly 101 is provided with a power socket 1012 and the water-cooled enclosure 104. The power socket 1012 is used for ultrasonic welding to a hollow conductive tube 1151 at one end of the liquid-cooled wire assembly 105. The water-cooled enclosure 104 is used to connect to a flexible liquid conduit 1152 at one end of the liquid-cooled wire assembly 105. The liquid-cooled socket housing 102 covers the charging socket flange assembly 101 and connects to one end of the liquid-cooled wire assembly 105. The other end of the liquid-cooled wire assembly 105 passes through the liquid-cooled socket housing 102, allowing coolant to be transferred through the water-cooled enclosure 104 to the flexible liquid conduit 1152 and circulate within the flexible liquid conduit 1152, exchanging heat with the hollow conductive tube 1151 and the entire liquid-cooled charging socket to achieve heat dissipation and cooling.

[0028] The water-cooled housing 104 is also equipped with a liquid inlet. During the charging process, under the action of the cooling pump, coolant flows into the water-cooled housing 104 through the liquid inlet and is then transported through the water-cooled housing 104 to the flexible liquid conduit 1152, where it circulates and achieves cooling. The coolant can be suitable for liquid media with insulating properties, such as deionized water, silicone oil, formulated oils, and other liquid media that meet the above requirements.

[0029] Specifically, in this embodiment, a water tank mounting hole 1011 is formed inside the charging socket flange assembly 101, and the water tank mounting hole 1011 is located between two power sockets 1012, for use with the second self-tapping screw 108 to install the water-cooled housing 104 inside the charging socket flange assembly 101. A water nozzle is formed on the water-cooled housing 104 to cooperate with the flexible liquid conduit 1152. Preferably, the flexible liquid conduit 1152 and the water nozzle of the water-cooled housing 104 are interference-fitted and sealed and locked with a clamp 110; the punched part of the hollow conductive tube 1151 is ultrasonically welded to the power socket 1012 of the charging socket flange assembly 101.

[0030] Preferably, a suitable amount of thermally conductive silicone grease with good thermal conductivity can be applied between the water-cooled housing 104 and the power socket 1012 to enhance the heat transfer capability.

[0031] As a further solution, the liquid-cooled charging socket also includes a power socket sealing ring 106, a power socket end cap 107, a grounding socket sealing ring 109, and a grounding socket end cap 111. The power socket sealing ring 106 and the power socket end cap 107 are fitted over the liquid-cooled wire assembly 105, with the power socket sealing ring 106 having an interference fit with the liquid-cooled socket housing 102. The power socket end cap 107, in conjunction with the liquid-cooled socket housing 102, seals the contact point between the end of the liquid-cooled wire assembly 105 away from the charging socket flange assembly 101 and the liquid-cooled socket housing 102. The grounding socket has an existing structure; the grounding socket sealing ring 109 and the grounding socket end cap 111 are fitted over the grounding socket, with a similar structural principle to the power socket sealing ring 106 and the power socket end cap 107, used to mate with the liquid-cooled socket housing 102 to achieve a sealed installation of the grounding socket.

[0032] In an optional embodiment, a mounting platform is formed on the outer surface of the charging socket flange assembly 101, and a mounting platform frame opening is formed on one end of the liquid-cooled socket housing 102 near the charging socket flange assembly 101. The charging socket flange assembly 101 and the liquid-cooled socket housing 102 are connected by the mounting platform engaging with the mounting platform frame opening. A plurality of threaded holes are also formed between the mounting platforms and the mounting platform frame opening, and a first self-tapping screw 103 is threaded through these threaded holes to connect the liquid-cooled socket housing 102 to the charging socket flange assembly 101.

[0033] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A liquid-cooled wire assembly, characterized in that, It consists of a hollow conductive tube, a flexible liquid conduit, and an insulating layer covering the hollow conductive tube and the flexible liquid conduit. The two ends of the hollow conductive tube are flattened and formed, and a transition area is formed near the flattening point. A strip-shaped through hole is punched in the transition area along its length. The flexible liquid conduit is set inside the hollow conductive tube, and its two ends pass through the through holes at both ends of the hollow conductive tube. The hollow conductive tube and the flexible liquid conduit at the same end are connected to the power socket of the liquid-cooled charging socket and the water-cooled box respectively. The coolant is transferred to the flexible liquid conduit through the water-cooled box and flows in the flexible liquid conduit to dissipate heat from the hollow conductive tube.

2. The liquid-cooled wire assembly according to claim 1, characterized in that, The via has a rounded corner.

3. The liquid-cooled wire assembly according to claim 1, characterized in that, The hollow conductive tube is welded to or threaded into the power socket.

4. The liquid-cooled wire assembly according to claim 1, characterized in that, The hollow conductive tube is a hollow copper tube or a hollow aluminum alloy tube.

5. A liquid-cooled charging socket, characterized in that, include: The charging socket flange assembly, the liquid-cooled socket housing, and the liquid-cooled wire assembly as described in any one of claims 1-4 are provided. The charging socket flange assembly is provided with a power socket and a water-cooled housing. The power socket is connected to a hollow conductive tube at one end of the liquid-cooled wire assembly. The water-cooled housing is connected to a flexible liquid conduit at the same end of the liquid-cooled wire assembly. The liquid-cooled socket housing covers one end of the charging socket flange assembly connected to the liquid-cooled wire assembly. The other end of the liquid-cooled wire assembly passes through the liquid-cooled socket housing.

6. The liquid-cooled charging socket according to claim 5, characterized in that, The water-cooled box is also equipped with a liquid inlet, which is connected to the cooling pump.

7. A liquid-cooled charging socket according to claim 5, characterized in that, The charging socket flange assembly has a water tank mounting hole located between two power sockets. This hole is used to install the water-cooled housing into the charging socket flange assembly with self-tapping screws.

8. A liquid-cooled charging socket according to claim 5, characterized in that, The flexible liquid conduit is interference-fitted to the water nozzle of the water-cooled box and locked with a clamp.

9. A liquid-cooled charging socket according to claim 5, characterized in that, Thermal grease is applied between the water-cooled housing and the power socket.

10. A liquid-cooled charging socket according to claim 5, characterized in that, The charging socket flange assembly is fastened to the liquid-cooled socket housing and secured with self-tapping screws.

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