High-power direct-current charging natural heat dissipation integrated cable

Abstract

A high-power direct-current charging natural heat dissipation integrated cable is characterized in that five circles of wires with insulating sheaths are coaxially arranged in an insulating jacket of the integrated cable from outside to inside, and each circle of wire is closely arranged in a circular ring shape; the number of the five circles of wires is twenty-four, eighteen, twelve, sixteen and five in sequence from outside to inside. The twenty-four thick wires in the first circle, the eighteen thick wires in the second circle and the twelve thick wires in the third circle are direct-current charging wires. The eight thin wires in the fourth circle are signal wires, and the remaining eight thin wires are auxiliary power wires; and one thick wire in the fifth circle is a grounding wire, and the rest four thin wires are signal shielding wires. According to the integrated cable, two existing positive and negative high-power wires are split into fifty-four small-diameter direct-current charging wires with insulating sheaths respectively, under the same bearing capacity, the integrated cable can be made thinner, lighter and softer, and the experience feeling of charging operation is greatly improved.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle charging technology, and in particular to a high-power DC charging natural heat dissipation integrated cable. Background Technology

[0002] Currently, the maximum charging current that domestically used natural heat dissipation charging cables can carry is 250A, and the slow charging speed is a major concern for car manufacturers and owners. With advancements in battery technology and the advent and application of liquid-cooled charging guns, the ability to achieve a range of 200-300 kilometers with just five minutes of charging for electric vehicles has become a reality. The working principle of a liquid-cooled charging gun is as follows: When the liquid-cooled charging gun connects to a liquid-cooled cable carrying a high current, it requires a circulating coolant to dissipate heat from the cable's power conductors and the power terminals within the charging gun. This necessitates a liquid chiller, which mainly consists of a power unit, a heat dissipation unit, and a control unit. The power unit comprises a liquid pump and a motor. The motor drives the liquid pump to continuously pump coolant into the liquid-cooled cable. The heat dissipation unit of the liquid chiller consists of microchannel heat sinks and a cooling fan. The hot coolant flows back to the microchannel heat sinks, where the cooling fan blows the heat into the air, cooling the coolant. The cooled coolant then returns to the power unit and is pumped back into the liquid-cooled cable and charging gun, repeating this cycle until charging is complete. While liquid-cooled charging gun systems can indeed achieve high-current charging and increase charging speed, they also have drawbacks: The motor and cooling fan consume electrical energy and generate noise during operation, which can disturb residents if the charging station is close to them; the coolant circulates within the charging gun and cables under pressure (at least 4 kg), creating a risk of leakage at connections such as the charging gun cable to the charging gun power terminal, the charging gun cable to the cable connector, and the liquid cooler to the liquid-cooled cable connector. Furthermore, a single liquid cooler is relatively expensive, costing approximately 4000 RMB.

[0003] In conclusion, while liquid-cooled charging guns and cables have certain advantages, their high cost and the risk of leakage are drawbacks. Therefore, both automakers and car owners currently desire a naturally cooled integrated cable capable of handling 600A without liquid cooling, and such a cable should be thin, lightweight, flexible, and offer a good ergonomic experience.

[0004] Appendix Figure 1The image shows a standard 250A naturally cooled integrated cable used both domestically and internationally. It has one DC+ and one DC- power line inside its insulating sheath, positioned side-by-side along the cable's diameter. The spaces formed by these two power lines and the inner wall of the insulating sheath house the PE ground wire and several signal lines and other functional lines, respectively. The remaining space is filled with material. Existing naturally cooled integrated cables have the following drawbacks:

[0005] Disadvantage 1: It can only carry a charging current of 250A, so the charging speed is not fast enough.

[0006] Disadvantage 2: The integrated cable has a relatively thick wire diameter, with an outer diameter of 40 mm. Because the power wires use 80 square millimeter conductors, the outer diameter of a single power wire is 18.5 mm, and the width of two power wires side-by-side is 37 mm. Adding the insulation sheath, the outer diameter of the integrated cable is 40 mm.

[0007] Disadvantage 3: The cable layout is not optimized. The PE ground wire and several signal and function lines are placed above and below the two power lines respectively. This asymmetrical layout has several drawbacks: First, the gaps are too large, requiring additional filler to fill them, resulting in a stiff, poorly rounded, and unsightly integrated cable. Second, the two power lines being placed side by side makes the integrated cable difficult to bend in one direction but easier to bend in the other, causing anisotropy in the bending direction. Third, bending the integrated cable can cause some signal lines to be excessively stretched and damaged.

[0008] Disadvantage 4: Poor ergonomics. The natural heat dissipation integrated cable connecting the charging gun is typically 5 meters long, with each meter weighing approximately 3.4 kilograms. The DC charging gun for electric vehicles weighs approximately 1.5 kilograms, totaling 18.5 kilograms. This weight is not convenient for charging operations. Utility Model Content

[0009] To overcome the shortcomings of the prior art, this utility model discloses a high-power DC charging natural heat dissipation integrated cable, which adopts the following technical solution:

[0010] A high-power DC charging naturally heat-dissipating integrated cable has five coils of self-insulating conductors coaxially arranged from the outside to the inside within the cable's insulating outer sheath. Each coil of conductors is arranged in a tightly packed circular pattern. The number of conductors in the five coils, from the outside to the inside, is 24, 18, 12, 16, and 5 respectively. Among them, one conductor in the first, second, third, and fifth coils is a thick conductor of the same diameter, while the remaining four conductors in the fourth and fifth coils are thin conductors of the same diameter. Functionally, the 24 thick conductors in the first coil, the 18 thick conductors in the second coil, and the 12 thick conductors in the third coil are DC charging wires; the eight thin conductors in the fourth coil are signal wires, and the remaining eight thin conductors are auxiliary power wires; the one thick conductor in the fifth coil is a grounding wire, and the remaining four thin conductors are shielding wires.

[0011] The technical solution is further improved by using copper lugs to connect the twelve DC charging cables in the first loop, the nine DC charging cables in the second loop, and the six DC charging cables in the third loop into a single DC+ power line, and connecting the remaining twelve DC charging cables in the first loop, the remaining nine DC charging cables in the second loop, and the remaining six DC charging cables in the third loop into a single DC- power line.

[0012] The technical solution was further improved. The eight signal lines in the fourth ring are temperature data transmission lines T1+, T1-, T2+, and T2-, and electronic lock connection lines PIN1, PIN2, EL+, and EL-. Terminal blocks are connected to both ends of the eight signal lines.

[0013] The technical solution is further improved by connecting the four auxiliary power lines in the fourth turn into a single DC+ auxiliary power line through the terminal block, and connecting the remaining four auxiliary power lines in the fourth turn into a single DC- auxiliary power line.

[0014] The technical solution was further improved. The four shielding wires in the fifth ring are CC1 wire, CC2 wire, S+ wire and S- wire respectively. A metal wire mesh shielding sleeve is set on the outside of the shielding wire, and a terminal is connected to each end of the shielding wire. Copper lugs are connected to each end of the grounding wire.

[0015] Further improvements to the technical solution include wrapping tape A around the fifth coil of conductor, wrapping tape B around the fourth coil of conductor, wrapping tape C around the third coil of conductor, wrapping tape D around the second coil of conductor, and wrapping tape E around the first coil of conductor; wrapping tapes A, B, C, D, and E are made of TPE, F46, or polyimide film tapes.

[0016] To further improve the technical solution, heat-absorbing and heat-conducting material is filled into the gaps between the first, second, and third coils of wire.

[0017] To further improve the technical solution, the heat-absorbing and heat-conducting material is paraffin wax.

[0018] After implementing the above technical solution, the beneficial effects of this utility model compared to the prior art are:

[0019] I. Strong Overcurrent Capacity. This integrated cable splits the existing two high-power positive and negative conductors into fifty-four small-diameter DC charging wires, each with its own insulating sheath. These fifty-four small-diameter DC charging wires are arranged in a tight circular pattern in the first, second, and third turns of the integrated cable. In use, the fifty-four small-power wires are combined to form two power wires. Comparing the split wires with a single, unsplit wire, although the total conductor cross-section of the split wires is the same as that of the unsplit single wire, their overcurrent capacity is completely different. After splitting a power wire into twenty-seven wires, its overcurrent capacity is 2.4 times higher than that of a single wire.

[0020] Second, excellent heat dissipation. This invention arranges fifty-four power wires in three circles, evenly distributed around the circumference. 24 power wires are close to the inner wall of the insulating outer sheath, 18 power wires are the next closest to the inner wall of the insulating outer sheath, and 12 power wires are the farthest from the inner wall of the insulating outer sheath. This arrangement of power wires results in a large heat dissipation surface area and the shortest heat dissipation radiation path, thus enabling it to carry a large charging current.

[0021] Third, the signal lines are not easily broken. The signal lines in this integrated cable are located inside the cable itself and are protected by two layers of power lines. Even during repeated bending, the cable is less prone to breakage. Figure 2 The integrated cable shown has a small displacement of the signal lines when bent, and will not break due to excessive stretching during bending.

[0022] IV. High tensile strength. (See attached image) Figure 2 The integrated cable shown has 54 power wires evenly distributed in three loops around the circumference. When the cable is pulled, the 54 power wires will be evenly stressed, which can effectively improve the tensile strength of the integrated cable.

[0023] V. Excellent ergonomics and user experience. (See attached image) Figure 1 The outer diameter of the 250A DC charging naturally cooled integrated cable shown is 40 mm, while the outer diameter of this naturally cooled integrated cable is 25 mm; (See attached image) Figure 1 The DC charging 250A natural heat dissipation integrated cable shown has a bending radius of 180 mm, while this integrated cable has a bending radius of 100 mm; (Attached) Figure 1 The DC charging 250A natural heat dissipation integrated cable shown weighs 3.4 kg per meter, while this integrated cable weighs 1.8 kg per meter and is thin, light, and flexible, providing an excellent ergonomic experience. Attached Figure Description

[0024] Appendix Figure 1 The diagram shown is a structural schematic of an existing 250A natural heat dissipation integrated cable.

[0025] Appendix Figure 2 The diagram shown is a structural schematic of this integrated cable.

[0026] In the attached diagram: 1. First coil of wire; 2. Second coil of wire; 3. Third coil of wire; 4. Fourth coil of wire; 5. Shielding wire; 6. Grounding wire; 7. Wrapping tape A; 8. Wrapping tape B; 9. Wrapping tape C; 10. Wrapping tape D; 11. Wrapping tape E; 12. Insulating outer sheath; 13. Heat-absorbing and heat-conducting material. Detailed Implementation

[0027] The preferred embodiments of this utility model are described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely used to explain the technical principles of this utility model and are not intended to limit the scope of protection of this utility model. It should be noted that in the description of this utility model, terms such as "front," "rear," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is merely for ease of description and does not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, it should not be construed as a limitation of this utility model. It should also be noted that in the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0028] A high-power DC charging naturally cooled integrated cable is used for charging new energy electric vehicles. Both ends of the integrated cable are connected to copper lugs or terminals for connecting to the charging gun and charging station, respectively.

[0029] As attached Figure 2 As shown, within the circular integrated cable insulation sheath 12, five coils of conductors with their own insulation sheaths are coaxially arranged from the outside in, with each coil of conductors arranged in a tight circular ring. From the outside in, the first coil 1 has twenty-four conductors, the second coil 2 has eighteen conductors, the third coil 3 has sixteen conductors, the fourth coil 4 has eighteen conductors, and the fifth coil 5 has four conductors.

[0030] In terms of thickness, one of the wires in the first loop (1), the second loop (2), the third loop (3), and the fifth loop (5) is a thick wire with the same diameter and specifications, while the remaining four wires in the fourth loop (4) and the fifth loop (5) are thin wires with the same diameter and specifications.

[0031] Functionally, the 24 thick wires in the first ring, the 18 thick wires in the second ring, and the 12 thick wires in the third ring are DC charging wires; the 8 thin wires in the fourth ring are signal wires, and the remaining 8 thin wires are auxiliary power wires; the 1 thick wire in the fifth ring is the grounding wire 6, and the remaining 4 thin wires are the shielding wires 5.

[0032] Cable assembly process:

[0033] After the fifth round of wires is assembled, it is secured by wrapping tape E11, which is made of polyimide film. The sixteen wires of the fourth round are tightly wrapped in a ring around wrapping tape E11 and secured by wrapping tape D10, which is also made of polyimide film. The twelve wires of the third round are tightly wrapped in a ring around wrapping tape D10, and then the gaps between the wires are filled with heat-absorbing and heat-conducting material 13. In this embodiment, the heat-absorbing and heat-conducting material 13 is paraffin wax. Finally, it is secured by wrapping tape C9, which is also made of polyimide film. The eighteen wires of the second round are tightly wrapped in a ring around wrapping tape C9, and then the gaps between the wires are filled with paraffin wax. Finally, it is secured by wrapping tape B8, which is also made of polyimide film. The first round of twenty-four wires is tightly wrapped in a circular loop around the wrapping tape B8. Paraffin wax is then filled into the gaps between the wires, and finally, the wrapping tape A7, which is a polyimide film tape, is wrapped around and secured the loop. Finally, an insulating outer sheath 12 is wrapped around the wrapping tape A7 using an injection molding machine.

[0034] To facilitate connection with charging guns and charging stations and enable the transmission of high-power DC power, during use, the twelve DC charging cables in the first loop, the nine DC charging cables in the second loop, and the six DC charging cables in the third loop are connected in parallel to form a DC+ power line using copper lugs. The remaining twelve DC charging cables in the first loop, the remaining nine DC charging cables in the second loop, and the remaining six DC charging cables in the third loop are connected in parallel to form a DC- power line. Then, the two ends of the DC+ power line and the DC- power line are connected to the charging gun and the charging station, respectively.

[0035] From the appendix Figure 1 and attached Figure 2 The comparison shows that: Figure 1 The DC+ and DC- charging power lines are each a separate wire, attached. Figure 2This involves splitting a single charging power line into twenty-seven individually insulated wires, which are then combined. The current-carrying capacity of these multiple wires is compared to that of a single, unsplit wire. Even if the cross-sectional area of ​​the combined wires is the same as that of the unsplit wire, their current-carrying capacity is completely different. Splitting a single wire into twenty-seven wires increases its current-carrying capacity by 2.4 times compared to a single wire.

[0036] Appendix Figure 1 The signal lines of the integrated cable are located within the area enclosed by the inner wall of the cable's insulation sheath 12 and the outer wall of the power lines, while the attached... Figure 2 The signal lines of the integrated cable are arranged within a loop formed by the power lines. During repeated bending, the cable... Figure 1 The signal lines of integrated cables with a large bending displacement are prone to breakage due to excessive stretching caused by bending. (See attached image) Figure 2 The signal lines of the integrated cable structure have small bending displacement and will not break due to excessive stretching during bending.

[0037] Appendix Figure 1 The integrated cable of the structure has an outer diameter of 40 mm, with... Figure 2 The integrated cable of the structure has an outer diameter of 25 mm; (attached) Figure 1 The integrated cable of the structure has a bending radius of 180 mm, with... Figure 2 The integrated cable of the structure has a bending radius of 100 mm; Figure 1 The integrated cable of the structure weighs 3.4 kg per meter, with... Figure 2 The integrated cable of the structure weighs 1.8 kg per meter; (with attached...) Figure 1 The integrated cables of the structure are thick, heavy, and stiff, with... Figure 2 The integrated cable structure is thin, light, and flexible, providing an excellent ergonomic experience.

[0038] The eight signal lines in the fourth ring are temperature data transmission lines T1+, T1-, T2+, and T2-, and electronic lock connection lines PIN1, PIN2, EL+, and EL-. Terminal blocks are connected to both ends of the eight signal lines.

[0039] In use, connect the four auxiliary power lines in the fourth turn into one DC+ auxiliary power line through the terminal blocks, and connect the remaining four auxiliary power lines in the fourth turn into one DC- auxiliary power line.

[0040] The four shielded wires 5 in the fifth ring are CC1, CC2, S+, and S-. A metal mesh shielding sleeve is installed on the outside of each shielded wire 5, and terminals are connected to both ends of each shielded wire 5. Copper lugs are connected to both ends of the grounding wire 6.

[0041] It should be noted that this integrated cable can be used with the GB20234.3-2015 electric vehicle DC charging gun, as well as the HPC supercharger gun (note: Chinese standard 7-pin DC charging gun), IEC 62196-3 DC American standard charging gun, IEC 62196-3 DC European standard charging gun, and IEC 62196-3 DC Japanese standard charging gun.

[0042] The parts not detailed herein are prior art. Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of protection of which is defined by the appended claims and their equivalents.

Claims

1. A high-power DC charging natural heat dissipation integrated cable, characterized in that: Inside the insulating sheath of the integrated cable, five coils of conductors with their own insulating sheaths are coaxially arranged from the outside in, with each coil arranged in a tight circular pattern. The number of conductors in the five coils from the outside in are 24, 18, 12, 16, and 5 respectively. Among them, one conductor in the first, second, third, and fifth coils is a thick conductor of the same diameter, while the remaining four conductors in the fourth and fifth coils are thin conductors of the same diameter. Functionally, the 24 thick conductors in the first coil, the 18 thick conductors in the second coil, and the 12 thick conductors in the third coil are DC charging wires; the eight thin conductors in the fourth coil are signal wires, and the remaining eight thin conductors are auxiliary power wires; the one thick conductor in the fifth coil is a grounding wire, and the remaining four thin conductors are shielding wires.

2. The high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: Connect the twelve DC charging cables in the first loop, the nine DC charging cables in the second loop, and the six DC charging cables in the third loop into a single DC+ power line using copper lugs. Connect the remaining twelve DC charging cables in the first loop, the remaining nine DC charging cables in the second loop, and the remaining six DC charging cables in the third loop into a single DC- power line.

3. The high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: The eight signal lines in the fourth ring are temperature data transmission lines T1+, T1-, T2+, and T2-, and electronic lock connection lines PIN1, PIN2, EL+, and EL-. Terminal blocks are connected to both ends of the eight signal lines.

4. The high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: Connect the four auxiliary power lines in the fourth turn into a single DC+ auxiliary power line using the terminal blocks, and connect the remaining four auxiliary power lines in the fourth turn into a single DC- auxiliary power line.

5. The high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: The four shielding wires in the fifth ring are CC1, CC2, S+, and S-. A metal wire mesh shielding sleeve is installed on the outside of the shielding wires, and terminals are connected to both ends of the shielding wires. Copper lugs are connected to both ends of the grounding wire.

6. A high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: in The fifth turn of the conductor is wrapped with tape A, the fourth turn of the conductor is wrapped with tape B, the third turn of the conductor is wrapped with tape C, the second turn of the conductor is wrapped with tape D, and the first turn of the conductor is wrapped with tape E; tapes A, B, C, D, and E are made of TPE, F46, or polyimide film tape.

7. The high-power DC charging natural heat dissipation integrated cable as described in claim 1, characterized in that: The gaps between the first, second, and third turns of the wire are filled with heat-absorbing and heat-conducting material.

8. The high-power DC charging natural heat dissipation integrated cable as described in claim 7, characterized in that: The heat-absorbing and heat-conducting material is paraffin wax.

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