New energy automobile liquid-cooled battery power cable
By introducing built-in and external cooling pipes, composite phase change material layers, and heat dissipation and cooling coatings into liquid-cooled cables, the problem of insufficient contact area between the coolant and the conductor is solved, achieving efficient heat dissipation and improved mechanical strength, and avoiding the risk of cable overheating.
Patent Information
- Application Number
- CN202520453702.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-14
- Publication Date
- 2026-02-24
- Estimated Expiration
- 2035-03-14
AI Technical Summary
The limited contact area between the coolant and the conductor in existing liquid-cooled cables results in incomplete heat absorption and dissipation, leading to low heat dissipation efficiency.
It adopts an internal and external cooling pipe structure, combined with a composite phase change material layer and a heat dissipation and cooling coating, to enhance the contact area and heat exchange effect between the coolant and the conductor. The turbulence effect is improved by needle-shaped fins and elliptical pits. Combined with the wear resistance of nylon tubes and the protection of Teflon tape, it forms a highly efficient heat dissipation system.
It significantly improves the heat dissipation efficiency of the cable, reduces the cable temperature, avoids the risk of overheating, extends the service life of the cable, and enhances the mechanical strength and wear resistance of the cable.
Smart Images
Figure CN223941582U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of cable technology, specifically relating to a power cable for liquid-cooled batteries in new energy vehicles. Background Technology
[0002] With the improvement of the new energy vehicle industry chain and supply chain system, and the enhancement of the competitiveness of new energy vehicle products, the supply level of new energy vehicles will be further improved, and the acceptance on the demand side will also be further increased. The rapid rise of the new energy vehicle industry has not only accelerated the electrification process of the domestic automobile industry, but also led the transformation and upgrading of the global automobile industry through technology export and market expansion.
[0003] Compared to traditional gasoline vehicles, new energy vehicles have advantages such as energy saving, environmental protection, strong power, and low operating costs, but their development is limited by low charging efficiency. To solve this problem, liquid-cooled high-power cables have emerged. By adding liquid-cooling pipes to the cable structure, the heat generated during charging can be effectively absorbed, thereby improving charging efficiency and extending the cable's service life.
[0004] Existing liquid-cooled cables have many shortcomings, such as limited contact area between the coolant and the conductor, resulting in incomplete heat absorption and dissipation, and low heat dissipation efficiency. Utility Model Content
[0005] To address the aforementioned technical problems, the purpose of this utility model is to provide a liquid-cooled battery power cable for new energy vehicles. This cable has high heat dissipation efficiency and stable heat dissipation effect, which can effectively reduce the cable temperature and avoid risks such as fire and battery leakage caused by overheating of the cable.
[0006] To achieve the above-mentioned technical objectives and effects, this utility model is implemented through the following technical solution:
[0007] This utility model provides a power cable for a liquid-cooled battery in a new energy vehicle, comprising, from the inside out, a cable core, a composite phase change material layer, an aluminum foil shielding layer, a braided shielding layer, and a sheath; the cable core includes multiple insulated cores, each insulated core including a built-in cooling tube in the middle, a built-in protective strip layer wrapped around the built-in cooling tube, multiple conductors disposed outside the built-in protective strip layer, and an outermost insulating layer; the wall of the built-in cooling tube has evenly distributed elliptical pits; the outer side of the sheath is provided with a heat dissipation and cooling coating.
[0008] Furthermore, the cable core is also provided with an external cooling pipe located between multiple insulated wire cores, and the outer side of the external cooling pipe is covered with an external protective tape layer.
[0009] Furthermore, the inner cooling pipe is also uniformly distributed with needle-shaped fins made of thermodeformable material on its pipe wall.
[0010] Furthermore, the conductor is wrapped around the periphery of the built-in protective strip layer in a diagonal or braided manner.
[0011] Furthermore, both the built-in cooling pipe and the external cooling pipe are nylon pipes.
[0012] Furthermore, the sheath is a TPV sheath.
[0013] Furthermore, a Teflon tape wrapping layer is provided between the braided shielding layer and the sheath.
[0014] Furthermore, both the built-in protective layer and the external protective layer are made of Teflon tape.
[0015] The method for preparing the power cable for the liquid-cooled battery of the new energy vehicle includes the following steps:
[0016] 1) Wrap an internal protective tape layer around the internal cooling pipe, then wrap a conductor layer around the internal protective tape layer, and finally wrap an insulation layer on the outermost layer to make an insulated wire core;
[0017] 2) Use multiple insulated wire cores as cable cores, wrap a composite phase change material layer around the cable cores, wrap an aluminum foil shielding layer around the composite phase change material layer, and then wrap a braided shielding layer around the aluminum foil shielding layer.
[0018] 3) A sheath is formed on the outermost layer using a melt extrusion process;
[0019] 4) Apply a heat dissipation and cooling coating to the sheath, and let it cure to form a heat dissipation and cooling coating.
[0020] Furthermore, the preparation process of the composite phase change material layer is as follows: the biomass fiber braided tape is immersed in the phase change material solution, and after full absorption, the composite phase change material tape is obtained; the composite phase change material tape is wrapped around the cable core.
[0021] The beneficial effects of this utility model are:
[0022] The insulated wire core of this utility model is provided with a built-in cooling tube. The conductor is covered with the built-in cooling tube, so that the conductor and the cooling tube are in full contact. The coolant flowing into the cooling tube can absorb heat more fully, thereby improving heat dissipation efficiency and heat dissipation effect.
[0023] The cable core of this utility model is also provided with an external cooling pipe located between the insulated wire cores, which can further improve the heat dissipation effect; at the same time, the external cooling pipe can also serve as a filler in the cable core, which can not only play a role in heat dissipation, but also improve the roundness of the cable and the strength of the cable core.
[0024] Both the built-in and external cooling pipes are wrapped with Teflon tape, which can provide protection and prevent damage to the cooling pipes during the manufacturing process.
[0025] The built-in cooling pipe of this invention has elliptical recesses on its wall, which can significantly increase the heat transfer area inside the pipe, enhance turbulence, and effectively break the boundary layer of the inner wall of the pipe, thereby enhancing the heat exchange effect between the coolant and the pipe wall.
[0026] In addition, the built-in cooling pipe of this utility model can also be provided with needle-shaped ribs made of thermal deformation material. When the temperature of a certain area of the cable is high, the needle-shaped ribs will undergo large thermal deformation, the flow area of the high temperature area will increase, the flow resistance will decrease, and the flow rate of coolant will increase, thereby cooling the high temperature area more specifically.
[0027] The composite phase change material layer in this invention can absorb heat through phase change when the cable temperature is high, thereby reducing the temperature of the surrounding environment. In conjunction with the built-in cooling pipe and the external cooling pipe, the cable can be cooled down more quickly. In addition, the composite phase change material layer can also maintain the cable temperature stability by releasing heat when the ambient temperature is low. Attached Figure Description
[0028] Figure 1 This is a schematic diagram of the structure of the liquid-cooled battery power cable for new energy vehicles according to this utility model.
[0029] Figure 2 This is a schematic diagram of the cross-sectional structure of the built-in cooling pipe in the power cable for a liquid-cooled battery in a new energy vehicle according to this utility model.
[0030] In the diagram, 1: Insulated core, 11: Built-in cooling tube, 111: Pits, 112: Needle-shaped ribs, 12: Built-in protective tape layer, 13: Conductor, 14: Insulation layer; 2: External cooling tube, 21: External protective tape layer; 3: Composite phase change material layer; 4: Aluminum foil shielding layer; 5: Braided shielding layer; 6: Teflon tape wrapping layer; 7: Sheath. Detailed Implementation
[0031] The technical solutions of this utility model will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0032] like Figure 1 and Figure 2As shown, this utility model provides a power cable for a liquid-cooled battery in a new energy vehicle, comprising, from the inside out, a cable core, a composite phase change material layer 3, an aluminum foil shielding layer 4, a braided shielding layer 5, and a sheath; the cable core includes multiple insulated cores 1, each insulated core 1 including a built-in cooling tube 11 in the middle, a built-in protective strip layer 12 wrapped around the built-in cooling tube 11, several conductors 13 disposed outside the built-in protective strip layer 12, and an outermost insulating layer 14; the conductors 13 are wrapped around the periphery of the built-in protective strip layer 12 by oblique wrapping or braiding; elliptical pits 111 are evenly distributed on the wall of the built-in cooling tube 11; the outer side of the sheath 7 is provided with a heat dissipation and cooling coating.
[0033] The built-in cooling pipe 11 of this invention has an elliptical recess 111 on its inner wall, which can significantly increase the heat transfer area inside the pipe, enhance turbulence, and effectively break the boundary layer of the inner wall of the pipe, thereby enhancing the heat exchange effect between the coolant and the pipe wall.
[0034] The inner cooling pipe 11 also has needle-shaped fins 112 made of thermodeformable material evenly distributed on its wall. When the temperature in a certain area of the cable is relatively high, the needle-shaped fins 112 undergo significant thermal deformation, increasing the flow area in the high-temperature area, reducing flow resistance, and increasing the flow rate of coolant in this area, thus providing more targeted cooling to the high-temperature area. The design of the needle-shaped fins provides a cooling regulation function, enabling more targeted heat dissipation.
[0035] To further improve heat dissipation, the cable core is also equipped with an external cooling pipe 2 located between multiple insulated cores 1, and the outer side of the external cooling pipe 2 is covered with an external protective tape layer 21. In addition, the external cooling pipe 2 can also serve as a filler in the cable core, which can not only dissipate heat but also improve the roundness of the cable and the strength of the cable core.
[0036] Coolant is introduced into both the built-in cooling pipe 11 and the external cooling pipe 2.
[0037] In addition, the inner wall of the external cooling pipe 2 can also be machined with elliptical recesses or have needle-like fins.
[0038] The built-in cooling pipe 11 and the external cooling pipe 2 are preferably nylon pipes, which have the characteristics of high strength, strong wear resistance and good chemical corrosion resistance. They can resist the erosion of chemicals such as acids, alkalis and salts and are suitable for various harsh environments.
[0039] Both the built-in protective layer 12 and the external protective layer 21 are made of Teflon tape, which can play a protective role and prevent damage to the cooling pipe during the processing.
[0040] The composite phase change material layer 3 is formed by wrapping a composite phase change material tape, which is made by impregnating a biomass fiber braided tape with phase change material. In this invention, the composite phase change material layer can absorb heat through phase change when the cable temperature is high, thereby reducing the ambient temperature. Combined with the built-in and external cooling pipes, it can achieve faster cable cooling. Furthermore, the composite phase change material layer can also maintain a stable cable temperature by releasing heat when the ambient temperature is low.
[0041] The aluminum foil shielding layer 4 is wrapped around the composite phase change material layer 3 using aluminum foil tape. The braided shielding layer 5 is made of tin-plated copper wire. The combination of the aluminum foil shielding layer 4 and the braided shielding layer 5 can achieve a superior shielding effect, effectively absorbing and dispersing external electromagnetic interference, and also providing the cable with high mechanical strength and flexibility.
[0042] To further improve the strength of the cable, a Teflon tape wrapping layer 6 is provided between the braided shielding layer 5 and the sheath 7.
[0043] The sheath 7 is a TPV sheath, which can withstand temperatures above 150°C and is also less expensive. The outer side of the sheath has a heat-dissipating and cooling coating, which is formed by applying a heat-dissipating and cooling paint to the sheath and then curing it.
[0044] The method for preparing the power cable for liquid-cooled batteries in new energy vehicles includes the following steps:
[0045] 1) Wrap an internal protective tape layer around the internal cooling pipe, then wrap a conductor layer around the internal protective tape layer, and finally wrap an insulation layer on the outermost layer to make an insulated wire core;
[0046] 2) Use multiple insulated wire cores as cable cores, wrap a composite phase change material layer around the cable cores, wrap an aluminum foil shielding layer around the composite phase change material layer, and wrap a braided shielding layer around the aluminum foil shielding layer; in this step, external cooling pipes located between the multiple insulated wire cores can also be filled into the cable cores.
[0047] 3) The outermost layer of the structure formed in step 2 is formed into a sheath through a melt extrusion process;
[0048] 4) Apply a heat dissipation and cooling coating to the sheath, and let it cure to form a heat dissipation and cooling coating.
[0049] The preparation process of the composite phase change material layer is as follows: the biomass fiber braided tape is immersed in the phase change material solution, and after full absorption, the composite phase change material tape is obtained; the composite phase change material tape is wrapped around the cable core.
[0050] The heat dissipation and cooling coating can preferably include the following components by mass: 30-40 parts epoxy resin, 2-3 parts reactive diluent, 1-2 parts dispersant, 3-5 parts curing agent, 2-3.5 parts nitrogen-boron compound, 2-3 parts titanium compound, and 0.01-0.03 parts graphene oxide powder.
[0051] Example
[0052] like Figure 1 and Figure 2 As shown, the new energy vehicle liquid-cooled battery power cable of this embodiment 1 includes, from the inside out, a cable core, a composite phase change material layer 3, an aluminum foil shielding layer 4, a braided shielding layer 5, a Teflon tape wrapping layer 6, and a sheath 7. In this embodiment, the cable core includes four insulated wire cores 1, each insulated wire core 1 including a built-in cooling tube 11 located in the middle, a built-in protective tape layer 12 wrapped around the built-in cooling tube 11, multiple conductors 13 disposed outside the built-in protective tape layer 11, and an outermost insulating layer 14. The conductors 13 are wrapped around the periphery of the built-in protective tape layer 12 by oblique wrapping or braiding. Elliptical pits 111 are evenly distributed on the tube wall of the built-in cooling tube 11. The cable core also has an external cooling tube 2 located between the multiple insulated wire cores 1, and the outer side of the external cooling tube 2 is covered with an external protective tape layer 21. Coolant is introduced into both the built-in cooling tube 11 and the external cooling tube 2. The outer side of the sheath 7 is provided with a heat dissipation and cooling coating.
[0053] The inner cooling pipe 11 also has needle-shaped fins 112 made of thermally deformable material evenly distributed on its pipe wall.
[0054] The built-in cooling pipe 11 and the external cooling pipe 2 are nylon pipes.
[0055] Both the built-in protective layer 12 and the external protective layer 21 are Teflon wrapping layers.
[0056] The composite phase change material layer 3 is formed by wrapping a composite phase change material tape, which is made by impregnating a biomass fiber woven tape with phase change material.
[0057] The aluminum foil shielding layer 4 is wrapped around the composite phase change material layer using an aluminum foil strip wrapping method. The braided shielding layer 5 is woven from tin-plated copper wire.
[0058] The sheath 7 is a TPV sheath, which can withstand high temperatures above 150°C and is also cheaper.
[0059] The outer side of the sheath 7 is provided with a heat dissipation and cooling coating, which is formed by coating the sheath with a heat dissipation and cooling paint and then curing it. In this embodiment, the heat dissipation and cooling paint includes the following components by mass: epoxy resin: 35 parts, reactive diluent: 2 parts, dispersant: 1 part, curing agent: 3 parts, nitrogen boron compound: 2 parts, titanium dioxide: 2 parts, and graphene oxide powder: 0.01 parts.
[0060] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention.
[0061] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. A power cable for a liquid-cooled battery in a new energy vehicle, characterized in that, The cable core comprises, from the inside out, a composite phase change material layer, an aluminum foil shielding layer, a braided shielding layer, and a sheath. The cable core includes multiple insulated cores, each of which includes a built-in cooling tube in the middle, a built-in protective strip layer wrapped around the built-in cooling tube, multiple conductors disposed outside the built-in protective strip layer, and an outermost insulating layer. The wall of the built-in cooling tube has elliptical pits evenly distributed. The outer side of the sheath is provided with a heat dissipation and cooling coating.
2. The new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that, The cable core is also provided with an external cooling pipe located between multiple insulated wire cores, and the outside of the external cooling pipe is covered with an external protective tape layer.
3. The new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that, The inner cooling pipe also has needle-shaped fins made of thermodeformable material evenly distributed on its wall.
4. The new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that, The conductor is wrapped around the outer periphery of the built-in protective strip layer in a diagonal or braided manner.
5. The new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that, Both the built-in cooling pipe and the external cooling pipe are nylon pipes.
6. The power cable for a liquid-cooled battery in a new energy vehicle according to claim 1, characterized in that, The sheath is a TPV sheath.
7. The new energy vehicle liquid-cooled battery power cable according to claim 1, characterized in that, A Teflon tape wrapping layer is also provided between the braided shielding layer and the sheath.
8. The power cable for a liquid-cooled battery in a new energy vehicle according to claim 1, characterized in that, Both the built-in protective layer and the external protective layer are made of Teflon tape.