Flat high-power charging pile cable
By designing a flat-structure charging pile cable and using flexible copper busbar conductors and special polyurethane elastomer materials, the problems of large bending radius and insufficient heat dissipation of traditional round cables are solved, achieving effective heat dissipation and flexible bending for high-power charging.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-15
- Publication Date
- 2026-03-17
AI Technical Summary
Traditional circular charging cable has a large bending radius when bent, which makes it difficult to meet the heat dissipation requirements of high-power fast charging, especially in scenarios with frequent bending or narrow spaces.
The charging pile cable adopts a flat structure, including flexible copper busbar conductors, power core insulation layer, ground core and signal unit, etc. It utilizes multi-layer thin copper foil and special polyurethane elastomer material to increase heat dissipation area and improve current carrying capacity.
It achieves effective heat dissipation under high-power charging conditions, avoids copper foil misalignment caused by frequent bending, and is suitable for efficient charging in confined spaces.
Smart Images
Figure CN224005679U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, and in particular to a flat high-power charging pile cable. Background Technology
[0002] In recent years, the global electric vehicle market has experienced explosive growth, and charging piles, as infrastructure, need to be built in large quantities simultaneously. This places higher demands on the performance, specifications, and quantity of charging pile cables.
[0003] Traditional circular charging pile cables have a relatively large bending radius when bent, which is especially inconvenient for some large-gauge cables in charging scenarios that require frequent bending or have limited space.
[0004] The electric vehicle market is increasingly demanding high-power fast charging. However, round cables rely primarily on surface heat dissipation, resulting in a relatively small heat dissipation area. During high-power charging, the cables generate significant heat, and the heat dissipation capacity of round cables is insufficient to meet the demands of rapid heat dissipation. Utility Model Content
[0005] The purpose of this utility model is to provide a flat high-power charging pile cable to solve the above-mentioned problems.
[0006] This utility model achieves the above objectives through the following technical solutions:
[0007] A flat high-power charging pile cable includes a flat, wear-resistant outer sheath. Inside the sheath, two symmetrical flexible copper busbar conductors are positioned in the center. Each flexible copper busbar conductor has a flat shape and is wrapped with a power core insulation layer. A ground core conductor is located on one side of the two power core insulation layers, and is also wrapped with a ground core insulation layer. The ground core insulation layer and the ground core conductor form a ground core. Two auxiliary core conductors are located between the ground core insulation layer and the two power core insulation layers. Each auxiliary core conductor is wrapped with an auxiliary core insulation layer, and the auxiliary core conductors and their insulation layers form auxiliary lines. On the other side of the two power core insulation layers, a signal unit tight-wrap layer is located. Inside the signal unit tight-wrap layer are multiple intertwined signal core conductors, each wrapped with signal core insulation. The signal core conductors and their insulation layers form a signal unit. Flexible filler is used to fill the spaces between the multiple signal core insulation layers and the signal unit tight-wrap layer.
[0008] Preferred: The flexible copper busbar conductor is made of multiple layers of thin copper foil that are rolled together, and the thin copper foil is stacked to a specified nominal cross-section after being processed by electric milling.
[0009] Preferred configuration: Auxiliary core conductor, ground core conductor, and signal core conductor are twisted together.
[0010] Preferably, the signal core conductor contains aramid Kevlar fibers.
[0011] Preferably, the signal unit's tight-pack layer is wrapped with thin non-woven fabric, and the power core's insulating layer is made of irradiated cross-linked rubber extrusion.
[0012] Preferred: The wear-resistant outer protective layer is made of special polyurethane elastomer.
[0013] The advantages compared to existing technologies are as follows:
[0014] 1. Flexible copper busbar conductors are made of multiple layers of thin copper foil, which have the advantages of being flexible, easy to bend, and having high current carrying capacity;
[0015] 2. The power core insulation layer is made of irradiated cross-linked rubber extrusion, which has high tensile strength and low Shore hardness. While being flexible, it can also restrain the flexible copper busbar conductor, avoiding adverse consequences such as copper foil misalignment caused by frequent bending during cable use.
[0016] 3. The cable is equipped with auxiliary wires, ground wire cores and signal units, which can realize the control, transmission and protection functions between the charging pile and the vehicle during the charging process according to system requirements;
[0017] 4. The wear-resistant outer sheath is made of special polyurethane elastomer, which has the advantages of good softness, wear resistance and water resistance;
[0018] 5. The use of multi-layer thin copper foil in a flat shape and the overall flat structure of the cable gives it a larger heat dissipation surface area. Under the same heat dissipation conditions, it effectively dissipates the heat generated by the flexible copper busbar conductor, thereby increasing the current carrying capacity of the cable by improving heat dissipation, and thus realizing high-power charging. Attached Figure Description
[0019] 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 these drawings without creative effort.
[0020] Figure 1 This is a cross-sectional view of a flat high-power charging pile cable as described in this utility model.
[0021] The annotations in the attached figures are explained as follows:
[0022] 1. Flexible copper busbar conductor; 2. Power core insulation layer; 3. Auxiliary core conductor; 4. Auxiliary core insulation layer; 5. Ground core conductor; 6. Ground core insulation layer; 7. Signal core conductor; 8. Signal core insulation; 9. Flexible filler; 10. Signal unit tight-packing layer; 11. Wear-resistant outer sheath. Detailed Implementation
[0023] In the description of this utility model, it should be noted that, 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; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0024] The present invention will be further described below with reference to the accompanying drawings:
[0025] like Figure 1 As shown, a flat high-power charging pile cable includes a flat, wear-resistant outer sheath 11. Two symmetrical flexible copper busbar conductors 1 are located in the middle of the inner part of the wear-resistant outer sheath 11. The flexible copper busbar conductors 1 have a flat shape. Each flexible copper busbar conductor 1 is wrapped with a power core insulation layer 2. A ground core conductor 5 is located on one side of the two power core insulation layers 2. The ground core conductor 5 is wrapped with a ground core insulation layer 6. The ground core insulation layer 6 and the ground core conductor 5 form a ground core. The ground core insulation layer 6 and the two power core insulation layers... Two auxiliary core conductors 3 are provided between the two power core insulation layers 2. Each auxiliary core conductor 3 is wrapped with an auxiliary core insulation layer 4. The auxiliary core conductor 3 and the auxiliary core insulation layer 4 form an auxiliary line. On the other side of the two power core insulation layers 2, there is a signal unit tight-packing layer 10. Inside the signal unit tight-packing layer 10, there are multiple intertwined signal core conductors 7. Each signal core conductor 7 is wrapped with a signal core insulation layer 8. The signal core conductor 7 and the signal core insulation layer 8 form a signal unit. The space between the multiple signal core insulation layers 8 and the signal unit tight-packing layer 10 is filled with a flexible filler 9.
[0026] In this embodiment: the flexible copper bus conductor 1 is made of multiple layers of thin copper foil and then rolled. The thin copper foil is stacked to a specified nominal cross-section after being processed by electric milling. The auxiliary core conductor 3, the ground core conductor 5, and the signal core conductor 7 are twisted together. The signal core conductor 7 contains aramid Kevlar fibers. The signal unit tight-packing layer 10 is wrapped with thin non-woven fabric. The power core insulation layer 2 is made of irradiated cross-linked rubber extrusion. The wear-resistant outer sheath 11 is made of special polyurethane elastomer. The flexible copper bus conductor 1 has the advantages of being soft, easy to bend, having a large heat dissipation area, and high current carrying capacity. The power core insulation layer 2 has high tensile strength and low Shore hardness. While being soft, it can also restrain the flexible copper bus conductor 1, avoiding adverse consequences such as copper foil misalignment due to frequent bending during cable use. The wear-resistant outer sheath 11 has the advantages of being soft, wear-resistant, and waterproof.
[0027] Working principle: The flexible copper busbar conductor 1 has the advantages of being soft, easy to bend, having a large heat dissipation area, and high current carrying capacity. The power core insulation layer 2 has high tensile strength and low Shore hardness. While being soft, it can also restrain the flexible copper busbar conductor 1, avoiding adverse consequences such as copper foil misalignment caused by frequent bending during cable use. The wear-resistant outer sheath 11 has the advantages of good softness, wear resistance, and water resistance. The cable has auxiliary wires, ground wire cores, and signal units inside, which can realize the control, transmission, and protection functions between the charging pile and the vehicle during the charging process according to system requirements. The flat flexible copper busbar conductor 1 and the flat appearance structure design give the cable a larger heat dissipation surface area. Under the same heat dissipation conditions, it can effectively dissipate the heat generated by the power core. By improving heat dissipation, the current carrying capacity of the cable is increased, thereby realizing high-power charging of electric vehicles.
[0028] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.
Claims
1. A flat high-power charging pile cable, characterized in that: The application relates to a flexible copper bar conductor (1) with a wear-resistant outer protective layer (11) in a flat structure, wherein two flexible copper bar conductors (1) in a flat structure are symmetrically arranged in the middle of the wear-resistant outer protective layer (11), the outer side of each flexible copper bar conductor (1) is wrapped with a power core insulating layer (2), one side of the two power core insulating layers (2) is provided with a ground wire core conductor (5), the outer side of the ground wire core conductor (5) is wrapped with a ground wire core insulating layer (6), the ground wire core insulating layer (6) and the ground wire core conductor (5) form a ground wire core, two auxiliary core conductors (3) are arranged between the ground wire core insulating layer (6) and the two power core insulating layers (2), the outer side of each auxiliary core conductor (3) is wrapped with an auxiliary core insulating layer (4), the auxiliary core conductor (3) and the auxiliary core insulating layer (4) form an auxiliary wire, the other side of the two power core insulating layers (2) is provided with a signal unit tight wrapping layer (10), the signal unit tight wrapping layer (10) is internally provided with a plurality of signal core conductors (7) which are twisted with each other, the outer side of each signal core conductor (7) is wrapped with a signal core insulating layer (8), the signal core conductor (7) and the signal core insulating layer (8) form a signal unit, and flexible filling (9) is filled between the plurality of signal core insulating layers (8) and the signal unit tight wrapping layer (10).
2. The flat high-power charging pile cable according to claim 1, characterized in that: The flexible copper bar conductor (1) is made of a plurality of thin copper foils which are stacked after electric milling and then are rolled.
3. The flat high-power charging pile cable according to claim 1, characterized in that: The auxiliary core conductor (3), the ground wire core conductor (5) and the signal core conductor (7) are twisted.
4. The flat high-power charging pile cable according to claim 1, characterized in that: The signal core conductor (7) is provided with aramid Kevlar fibers.
5. The flat high-power charging pile cable according to claim 1, characterized in that: The signal unit tight wrapping layer (10) is wrapped with light and thin non-woven fabric, and the power core insulating layer (2) is extruded by irradiation cross-linking rubber.
6. The flat high-power charging pile cable according to claim 1, characterized in that: The wear-resistant outer protective layer (11) is made of special polyurethane elastomer.