Liquid-cooled cable

Abstract

The utility model discloses a liquid cooling cable, comprising at least two power lines and at least two liquid cooling pipes, and the at least two liquid cooling pipes are respectively arranged in the two power lines. The liquid cooling pipe comprises a heat conduction layer and an explosion-proof layer wrapping the heat conduction layer. The power line comprises a conductor and an outer protective layer wrapping the conductor. The conductor wraps the outer wall of the explosion-proof layer. The heat conduction layer is in direct contact with the internal cooling liquid. In the working process of the liquid-cooled cable, the conductor continuously generates heat, the flow of the internal cooling liquid is increased, the heat conduction layer accelerates heat exchange between the cooling liquid and the conductor, and cooling of the liquid-cooled cable is promoted. And meanwhile, the pressure of the cooling liquid in the heat conduction layer is continuously increased, and the explosion-proof layer provides support for the heat conduction layer, so that explosion is prevented, the use risk is reduced, and the working stability of the liquid-cooled cable at high temperature and high pressure is improved. And meanwhile, the internal structure of the cable can be flexibly adjusted according to different working conditions to adapt to different product requirements.

Description

Technical Field

[0001] This utility model relates to the field of charging technology, specifically to a liquid-cooled cable. Background Technology

[0002] With the continuous development of the electric vehicle market, high-efficiency and fast high-power charging guns have attracted the attention of relevant companies and customers in the industry. How to design safe and effective high-power charging guns has become a core technology in the industry.

[0003] As market demands for high-power charging guns continue to rise, the power loss during use also increases, making the issue of cooling high-power charging guns increasingly critical. Currently, optimizing the heat dissipation of high-power liquid-cooled charging guns faces two major challenges: first, the thermal conductivity of cable-isolated liquid-cooled cables is poor, meaning that even increasing the power of the liquid cooling system does not significantly improve heat dissipation efficiency; second, with the continuous increase in the operating power of both the charging gun and the liquid cooling system, the flow rate of the coolant and the rate of temperature rise in the charging gun also increase, simultaneously raising the requirements for the heat resistance and coolant pressure resistance of the liquid-cooled cables. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a liquid-cooled cable that can improve heat dissipation and ensure the stability of the cable under high temperature and high flow rate conditions.

[0005] This utility model proposes a liquid-cooled cable, including at least two power lines and at least two liquid-cooling tubes, wherein the at least two liquid-cooling tubes are respectively disposed inside the two power lines;

[0006] The liquid cooling pipe is used to transport coolant. The liquid cooling pipe includes a heat-conducting layer and an explosion-proof layer. The explosion-proof layer covers the outer wall of the heat-conducting layer, and coolant flows inside the heat-conducting layer.

[0007] The power line includes a conductor and an outer sheath, the outer sheath covering the outer wall of the conductor, and the conductor covering the outer wall of the explosion-proof layer.

[0008] In one embodiment, the liquid-cooled cable further includes a cable sheath having a receiving cavity, within which the power line and the liquid-cooling pipe are disposed.

[0009] In one embodiment, the cavity is further provided with signal lines, ground lines and filler.

[0010] In one embodiment, the explosion-proof layer is formed by weaving a mesh and / or wrapping a strip.

[0011] In one embodiment, the strip is any one or more of polyester tape and nonwoven fabric.

[0012] In one embodiment, the woven mesh is any one or more of metal wire, glass wire, bulletproof wire, and nylon wire.

[0013] In one embodiment, the woven mesh is made of bulletproof yarn, and the outer wall of the woven mesh has a protective adhesive layer.

[0014] The liquid-cooled cable of this utility model includes at least two power lines and at least two liquid-cooling tubes, with the at least two liquid-cooling tubes respectively disposed inside two power lines. Each liquid-cooling tube includes a heat-conducting layer and an explosion-proof layer covering the heat-conducting layer. Each power line includes a conductor and an outer sheath covering the conductor. The conductor is encased in the outer wall of the explosion-proof layer. The heat-conducting layer is in direct contact with the internal coolant. During the operation of the liquid-cooled cable, the conductor continuously generates heat, increasing the internal coolant flow rate. The heat-conducting layer accelerates heat exchange between the coolant and the conductor, promoting cooling of the liquid-cooled cable. Simultaneously, the coolant pressure within the heat-conducting layer also continuously increases. The explosion-proof layer provides support for the heat-conducting layer, preventing bursting, reducing usage risks, and improving the operational stability of the liquid-cooled cable under high temperature and high pressure. Furthermore, the internal structure of the cable can be flexibly adjusted according to different operating conditions to adapt to different product requirements. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0016] Figure 1 This is a cross-sectional structural schematic diagram of an embodiment of the liquid-cooled cable of this utility model;

[0017] Figure 2 This is a cross-sectional structural schematic diagram of an embodiment of the liquid-cooled cable of this utility model;

[0018] Explanation of icon numbers:

[0019]

[0020] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. 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] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0023] In this utility model, unless otherwise explicitly specified and limited, the terms "connection," "fixing," etc., should be interpreted broadly. For example, "fixing" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0024] Furthermore, in this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the word "and / or" throughout the text means including three parallel solutions; taking "A and / or B" as an example, it includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0025] With the continuous development of the electric vehicle market, high-efficiency and fast high-power charging guns have attracted significant attention from industry players and customers. Designing safe and effective high-power charging guns has become a core technology in the industry. As market demands for high-power charging guns continue to rise, the power loss during use also increases, making the cooling problem of high-power charging guns increasingly serious. Currently, optimizing the heat dissipation of high-power liquid-cooled charging guns faces two major challenges: first, the thermal conductivity of cable-isolated liquid-cooled cables is poor, and even with increased liquid-cooling system power, the improvement in heat dissipation efficiency is not ideal; second, as the operating power of the charging gun and the liquid-cooling system continues to increase, the flow rate of the coolant and the temperature rise rate of the charging gun also increase, simultaneously raising the requirements for the heat resistance and coolant pressure resistance of the liquid-cooled cables.

[0026] This utility model proposes a liquid-cooled cable. Please refer to... Figures 1 to 2 It includes at least two power lines 1 and at least two liquid cooling pipes 2, with the at least two liquid cooling pipes 2 respectively disposed inside the two power lines 1; the liquid cooling pipes 2 are used to transport coolant, and the liquid cooling pipes 2 include a heat-conducting layer 21 and an explosion-proof layer 22, the explosion-proof layer 22 covering the outer wall of the heat-conducting layer 21, and coolant flowing inside the heat-conducting layer 21; the power line 1 includes a conductor 11 and an outer sheath 12, the outer sheath 12 covering the outer wall of the conductor 11, and the conductor 11 covering the outer wall of the explosion-proof layer 22.

[0027] In this embodiment, the liquid-cooled cable can be designed with different structures depending on the operating conditions, including at least two power lines 1 and at least two liquid-cooling pipes 2. The power line 1 includes a conductor 11 and an outer sheath 12 covering the outer wall of the conductor 11. The conductor 11 is made of conductive material and can connect to an external charging device to conduct a circuit. The conductor 11 can be a single wire or a combination of multiple wires. It is understood that using multiple wires braided to form the conductor 11 can enhance the current-carrying capacity of the conductor 11 while preventing the conductor bundle from becoming loose. Preferably, the conductor 11 can adopt a copper wire braided layer structure. During the use of the liquid-cooled cable, the conductor continuously generates heat. The liquid-cooling pipe 2 contains a coolant, which can be water, oil, or ethylene glycol, etc. The coolant exchanges heat with the conductor 11 through the pipe wall of the liquid-cooling pipe 2, dissipating heat and cooling the conductor 11. The liquid cooling pipe includes a heat-conducting layer 21 made of a material with high thermal conductivity. Coolant flows through the inner wall of the heat-conducting layer 21, allowing direct contact between the inner wall and the coolant. The heat-conducting layer 21 increases the thermal conductivity between the conductor 11 and the coolant, effectively improving the heat dissipation efficiency of the liquid-cooled cable. As the operating power of the liquid-cooled cable increases, the flow rate of the coolant and the temperature rise of the conductor 11 also increase, leading to a continuous increase in the coolant pressure within the liquid cooling pipe 2. The outer wall of the heat-conducting layer 21 is covered with an explosion-proof layer 22. The explosion-proof layer 22 has high material toughness and mechanical strength. It is positioned between the heat-conducting layer 21 and the conductor 11, providing tight support for the heat-conducting layer 21 and preventing it from bursting under high-temperature and high-pressure operating conditions. The conductor 11 is covered by the outer wall of the explosion-proof layer 22, allowing the heat generated on the conductor 11 to be transferred through the explosion-proof layer 22 to the heat-conducting layer 21, and then to the coolant within the heat-conducting layer 21, thereby reducing the heat on the conductor 11. The composite structure of liquid cooling pipe 2 effectively improves the heat dissipation efficiency of the liquid-cooled cable and the stability of the fluid circuit under high-flow-rate coolant. It enhances the heat resistance and coolant pressure resistance of the liquid-cooled cable, ensuring its operational stability and extending product lifespan while maintaining its heat dissipation efficiency.

[0028] In one embodiment, please refer to Figure 1 The liquid-cooled cable includes four power lines 1 and four liquid-cooling tubes 2, with each power line 1 containing a liquid-cooling tube 2. Each power line 1 has a conductor 11 and an outer layer 12 covering the conductor 11. The four conductors 11 include two positive conductors and two negative conductors. The conductors 11 are located on the outer wall of the liquid-cooling tubes 2. The coolant inside the liquid-cooling tubes 2 exchanges heat with the conductors 11 through a heat-conducting layer 21 and an explosion-proof layer 22, carrying away the heat generated by the conductors 11 during operation and cooling the liquid-cooled cable.

[0029] In another embodiment, please refer to Figure 2The liquid-cooled cable includes two power lines 1 and four liquid-cooling tubes 2. The two conductors 11 include one positive conductor and one negative conductor. Two liquid-cooling tubes 2 are respectively disposed within two power lines 1 for the inflow of coolant. The other two liquid-cooling tubes 2 are arranged adjacent to the power lines 1 for the outflow of coolant. This type of liquid-cooled cable has a smaller wire diameter and can be used in operating environments with high power requirements and high wire diameter requirements.

[0030] Understandably, the internal structure design of liquid-cooled cables can be adjusted according to different working conditions and requirements.

[0031] Further, please refer to Figure 1 The liquid-cooled cable also has a cable sheath 5, which has a housing cavity containing a power line 1 and a liquid-cooling pipe 2.

[0032] In this embodiment, the cable sheath 5 can be made of a high-strength, tensile-resistant insulating material to prevent leakage during operation of the liquid-cooled cable and provide insulation protection. The cable sheath 5 has a housing cavity containing a power line 1, a liquid-cooled pipe 2, a signal line 3, a ground wire 4, and filler. The cable sheath 5 allows the wire bundle within the housing cavity to be assembled into a single unit. The signal line 3 includes at least one signal conductor and a signal line sheath covering the signal conductor. The ground wire 4 is used to transfer high voltage to the ground, reducing the risk of electric shock.

[0033] This utility model provides an embodiment, please refer to it. Figure 1 The heat-conducting layer 21 is made of a heat-conducting material.

[0034] Specifically, the heat-conducting layer 21 is preferably an insulating material with high thermal conductivity. During the operation of the liquid-cooled cable, the coolant can quickly exchange heat with the conductor 11 through the heat-conducting layer 21, rapidly transferring the heat generated by the conductor 11 and accelerating the cooling of the liquid-cooled cable.

[0035] This utility model provides an embodiment, please refer to it. Figure 1 The explosion-proof layer 22 is made of woven mesh and / or wrapped with strips.

[0036] Specifically, the explosion-proof layer 22 can wrap around and support the heat-conducting layer 21 to prevent the heat-conducting layer 21 from bursting under internal high-pressure conditions. The explosion-proof layer 22 can be formed by weaving a mesh and / or wrapping a strip. The strip can be any one or more types of polyester tape or non-woven fabric. The strip can be wound in a spiral manner. It is understood that the explosion-proof layer 22 can be woven using a mesh alone or wrapped using a strip alone, or a combination of both. The mesh can be placed inside or outside the strip; there is no limitation on this. Preferably, the strip can be a polyester tape wound in a spiral manner, with a polyester tape overlap rate greater than 1%.

[0037] Furthermore, the woven mesh is any one or more of metal wire, glass wire, bulletproof wire, and nylon wire. Preferably, the weaving density of the woven mesh is greater than 70%.

[0038] In one embodiment, the woven mesh can be made of copper wire. The copper wire woven mesh serves as both an explosion-proof element and a conductor 11.

[0039] In another embodiment, the woven mesh is made of bulletproof yarn, and the outer wall of the woven mesh has a protective adhesive layer formed by over-adhesion, which provides additional protection for the explosion-proof layer 22 and further enhances the mechanical strength of the explosion-proof layer 22.

[0040] The liquid-cooled cable of this invention employs a composite structure where a heat-conducting layer 21 is covered by an explosion-proof layer 22, with the interior of the heat-conducting layer 21 in direct contact with the coolant. During operation, the conductor 11 continuously generates heat, increasing the internal coolant flow rate. This heat exchange between the coolant and conductor 11 is accelerated through the heat-conducting layer 21, promoting cooling of the liquid-cooled cable. Simultaneously, the coolant pressure within the heat-conducting layer 21 also continuously increases. The explosion-proof layer provides support for the heat-conducting layer 21, preventing bursting, reducing operational risks, and improving the operational stability of the liquid-cooled cable under high temperature and pressure. Furthermore, the internal structure of the cable can be flexibly adjusted according to different operating conditions to adapt to various product requirements.

[0041] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A liquid-cooled cable, comprising at least two power lines (1) and at least two liquid-cooled pipes (2), the at least two liquid-cooled pipes (2) being respectively arranged inside the two power lines (1); characterized in that The liquid-cooled pipe (2) is used for transmitting cooling liquid, and comprises a heat-conducting layer (21) and an explosion-proof layer (22), the explosion-proof layer (22) being wrapped on the outer wall of the heat-conducting layer (21), and the heat-conducting layer (21) being internally circulated with cooling liquid; The power line (1) comprises a conductor (11) and an outer protective layer (12), the outer protective layer (12) being wrapped on the outer wall of the conductor (11), and the conductor (11) being wrapped on the outer wall of the explosion-proof layer (22).

2. The liquid-cooled cable of claim 1, wherein, Further comprising a cable outer sheath (5) having a containing cavity, the containing cavity being internally provided with the power line (1) and the liquid-cooled pipe (2).

3. The liquid-cooled cable of claim 2, wherein, The containing cavity is further internally provided with a signal line (3), a ground line (4) and a filler.

4. The liquid-cooled cable of claim 1, wherein, The explosion-proof layer (22) is woven by a woven mesh and / or wrapped by a tape.

5. The liquid-cooled cable of claim 4, wherein, The tape is any one or several of polyester tape and non-woven fabric.

6. The liquid-cooled cable of claim 4, wherein, The woven mesh is any one or several of metal wire, glass wire, bulletproof wire and nylon wire.

7. The liquid-cooled cable of claim 6, wherein, The woven mesh is woven by bulletproof wire, and the outer wall of the woven mesh is provided with a protective glue layer.

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