Flame-retardant super fast charging cable for interior of new energy automobile

Abstract

The utility model belongs to the field of manufacturing of high-voltage connecting cables for the interior of new energy automobiles, and discloses a flame-retardant super fast charging cable for the interior of a new energy automobile, which comprises a DC + end and a DC-end, reinforced protection filling is arranged between the DC + end and the DC-end, and metal composite wrapping layers are arranged on the peripheries of the DC + end, the DC-end and the reinforced protection filling. The periphery of the metal composite wrapping layer is provided with a metal braid layer, the periphery of the metal braid layer is provided with a flame-retardant layer, the periphery of the flame-retardant layer is provided with a sheath, and the DC + end and the DC-end are of the same structure and are symmetrically arranged; the DC + end and the DC-end respectively comprise a liquid cooling pipe and a return pipe which are arranged side by side, a copper conductor is arranged on the periphery of the liquid cooling pipe, and an insulating layer is arranged on the periphery of the copper conductor. According to the flame-retardant super fast charging cable for the interior of the new energy automobile, the flame-retardant super fast charging cable for the interior of the new energy automobile can bear DC600A current, and the current-carrying capacity is improved; and the copper consumption of the conductor is reduced, the weight of the charging wire in the automobile is reduced, and the lightweight development of the automobile is facilitated.

Description

Technical Field

[0001] This utility model belongs to the field of manufacturing high-voltage connection cables for internal use in new energy vehicles, and in particular relates to a flame-retardant super-fast charging cable for internal use in new energy vehicles. Background Technology

[0002] With the continuous expansion of the new energy vehicle market and the increasing demand from consumers for charging efficiency, liquid-cooled charging technology will be adopted in more cities and stations. The first batch of supercharging stations in the market, featuring a 1000V high-voltage technology platform and a 600kW liquid-cooled charging pile, has already been put into operation. The in-vehicle charging cable connecting the charging port and the battery achieves the 600A current carrying capacity requirement by increasing the copper conductor cross-section to 150mm². This solution increases the overall vehicle cost and does not align with the trend towards lightweight vehicles. Furthermore, accidental charging, where the charging current far exceeds the current carrying capacity of the in-vehicle cables, reduces the lifespan of the charging cables and, in severe cases, can cause vehicle fires. Therefore, considering overall vehicle cost, lightweight design, and safety, a flame-retardant super-fast charging cable for use inside new energy vehicles needs to be designed. Utility Model Content

[0003] The purpose of this invention is to provide a flame-retardant super-fast charging cable for use inside new energy vehicles, in order to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution:

[0005] A flame-retardant super-fast charging cable for use inside new energy vehicles includes a DC+ terminal and a DC- terminal. A reinforced protective filler is provided between the DC+ terminal and the DC- terminal. A metal composite wrapping layer is provided around the DC+ terminal, the DC- terminal, and the reinforced protective filler. A metal braided layer is provided around the metal composite wrapping layer. A flame-retardant layer is provided around the metal braided layer. A sheath is provided around the flame-retardant layer. The DC+ terminal and the DC- terminal have the same structure and are symmetrically arranged. Each DC+ terminal and DC- terminal includes a liquid-cooling pipe and a return pipe arranged side-by-side. A copper conductor is provided around the liquid-cooling pipe, and an insulation layer is provided around the copper conductor. A hydraulic sensing core, a temperature sensing core, and a liquid level sensing core are provided around the return pipe.

[0006] Furthermore, the reinforcing protective filler is made of silicone rubber material with a temperature resistance of -40℃ to 150℃, and the internal reinforcing core is aramid Kevlar.

[0007] Furthermore, both the liquid cooling pipe and the return pipe are made of PA12 tubing. The specifications (outer diameter / inner diameter) of the liquid cooling pipe are φ12 / φ10mm, and the specifications (outer diameter / inner diameter) of the return pipe are φ8 / φ6mm.

[0008] Furthermore: the copper conductor has a specification of 35mm. 2 The conductor wire diameter is selected as φ0.200±0.003mm.

[0009] Furthermore, the insulation layer is made of a low-smoke, halogen-free irradiated polyolefin material with a temperature resistance of -40°C to 150°C.

[0010] Furthermore: the hydraulic sensing wire core, the temperature sensing wire core, and the liquid level sensing wire core all use 0.75mm wire. 2 conductor.

[0011] Furthermore, the metal composite wrapping layer is made of aluminum-plastic composite strip with a thickness of 0.05 mm and a width of 40 mm.

[0012] Furthermore, the metal braided layer uses tin-plated copper wire with a diameter of φ0.200±0.003mm and a braiding density of 85%-90%.

[0013] Furthermore, the flame-retardant layer is made of glass fiber tape with a thickness of 0.15 mm and a width of 40 mm.

[0014] Furthermore, the sheath is made of a low-smoke, halogen-free, radiation-retardant Class A polyolefin material with a temperature resistance of -40℃ to 150℃.

[0015] Compared with existing technologies, the beneficial effects are:

[0016] 1. Flame-retardant supercharging cables used inside new energy vehicles can carry DC 600A current, thus increasing current carrying capacity;

[0017] 2. The reduced amount of copper used in the conductor lowers the weight of the in-vehicle charging cable, contributing to the development of lightweight automobiles;

[0018] 3. It can transmit battery temperature and terminal temperature, automatically adjust coolant flow and charging current to improve charging safety and make charging more intelligent;

[0019] 4. Use the liquid cooling equipment of the external charging station to cool the charging cables inside the vehicle. Attached Figure Description

[0020] Figure 1 This is a structural schematic diagram of a flame-retardant super-fast charging cable for use inside new energy vehicles, as described in this utility model.

[0021] Figure 2 This is a schematic diagram of the reinforced protective filling section of a flame-retardant super-fast charging cable for use inside a new energy vehicle, as described in this utility model.

[0022] In the attached diagram, the following are the reference numerals: 1. Liquid cooling pipe; 2. Copper conductor; 3. Insulation layer; 4. Metal composite wrapping layer; 5. Metal braided layer; 6. Flame retardant layer; 7. Sheath; 8. Return pipe; 9. Temperature sensing core; 10. Liquid level sensing core; 11. Hydraulic sensing core; 12. Reinforced protective filler. Detailed Implementation

[0023] 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.

[0024] Please see Figures 1-2 A flame-retardant super-fast charging cable for use inside new energy vehicles includes a DC+ terminal and a DC- terminal. A reinforced protective filler 12 is provided between the DC+ terminal and the DC- terminal. A metal composite wrapping layer 4 is provided around the DC+ terminal, the DC- terminal and the reinforced protective filler 12. A metal braided layer 5 is provided around the metal composite wrapping layer 4. A flame-retardant layer 6 is provided around the metal braided layer 5. A sheath 7 is provided around the flame-retardant layer 6. The DC+ terminal and the DC- terminal adopt the same structure and are symmetrically arranged. The DC+ terminal and the DC- terminal respectively include a liquid cooling pipe 1 and a return pipe 8 arranged side by side. A copper conductor 2 is provided around the liquid cooling pipe 1. An insulation layer 3 is provided around the copper conductor 2. A hydraulic sensing core 11, a temperature sensing core 9 and a liquid level sensing core 10 are provided around the return pipe 8.

[0025] The reinforced protective filler 12 is made of silicone rubber material with a temperature resistance of -40℃ to 150℃, and the internal reinforcing core is aramid Kevlar, which is extruded through a special-shaped mold. Figure 2 It features irregular filling with six strands of aramid Kevlar with a fineness of 600D at the center.

[0026] Both the liquid cooling pipe 1 and the return pipe 8 are made of PA12 tubing, with a melting point of 180℃, a water absorption of 0.2% in water over 24 hours, a water saturation rate of 1.5%, a tensile strength of 55MPa, an elongation at break of 150% at -40℃, an elongation at break of 250% at 23℃, a flexural modulus of 1330MPa, a Rockwell hardness of 105R, a heat distortion temperature of 160℃ under 0.5MPa pressure, and a heat distortion temperature of 60℃ under 1.9MPa pressure. The specifications (outer diameter / inner diameter) of the liquid cooling pipe 1 are φ12 / φ10mm, and the specifications (outer diameter / inner diameter) of the return pipe 8 are φ8 / φ6mm.

[0027] The copper conductor 2 is 35mm² 2The conductor wire diameter is selected as φ0.200±0.003mm. 46 φ0.200 single wires are twisted into a stranded wire of φ1.6mm according to the pitch ratio of 16-20. The stranded wire is twisted into 24 strands. With the liquid cooling pipe 1φ12 / φ10 as the center of the conductor, the 24 strands are wound around the outer wall of the liquid cooling pipe 1 according to the pitch ratio of 14-16. The outer diameter after winding is 15.2mm.

[0028] Insulation layer 3 is made of low-smoke halogen-free irradiated polyolefin material with a temperature resistance of -40℃ to 150℃. The strength of the insulation before irradiation is 10MPa, the elongation at break is ≥400%, it meets the requirements for low-temperature embrittlement at 40℃, and the volume resistivity at 20℃ is ≥10. 15 Ω.cm, meeting the group's low smoke and halogen-free requirements, Shore hardness 85±2A, extrusion insulation is extruded, average insulation thickness ≥1.5mm, thinnest point ≥1.20mm, outer diameter after extrusion 18.2mm-18.6mm.

[0029] Hydraulic sensing core 11, temperature sensing core 9, and level sensing core 10 all use 0.75mm thick wire. 2 The conductor and insulation are made of the same temperature resistance grade as the insulation layer 3, with an average thickness of ≥0.5mm, a minimum thickness of ≥0.4mm, an outer diameter of 2.1mm-2.4mm, a tensile strength of insulation after irradiation of ≥12MPa, and an elongation at break of ≥400%, meeting the requirements of standard ISO 19642-5.

[0030] The metal composite wrapping layer 4 is made of aluminum-plastic composite strip with a thickness of 0.05mm and a width of 40mm, with the aluminum side facing outwards and in contact with the metal braided layer 5.

[0031] The metal braided layer 5 uses tin-plated copper wire with a diameter of φ0.200±0.003mm and a braiding density of 85%-90%.

[0032] The flame-retardant layer 6 is made of 0.15mm thick and 40mm wide glass fiber tape, wrapped in two layers, with the inner layer wrapped to the left and the outer layer wrapped to the right, with an overlap rate of 20%-30%.

[0033] The sheath 7 is made of low-smoke halogen-free irradiated flame-retardant Class A polyolefin material with a temperature resistance of -40℃ to 150℃. It is produced by extrusion, with an average thickness of ≥1.7mm and a minimum thickness of ≥1.35mm. The extruded outer diameter is (57.7±0.3)mm*(23.5±0.3)mm. The performance of the irradiated cable meets all the indicators of ISO 19642-9.

[0034] Working principle: The DC+ and DC- terminals form a current loop. Liquid cooling pipe 1 is connected to the liquid-cooled charging gun via a quick-seal connector between the nozzle and the charging port, forming a cooling channel for the charging cable inside the vehicle. The charging cable is cooled by the liquid cooling medium of the charging pile. Copper conductor 2 covers the outside of liquid cooling pipe 1 to transmit charging current. Insulation layer 3 covers the outside of the conductor to prevent current leakage and isolates copper conductor 2 from the metal composite wrapping layer 4, preventing short circuits that could damage equipment or affect personal safety. Return pipe 8 connects to the charging gun via a quick-seal connector between the nozzle and the charging port. The return pipe 8 is connected to form a liquid-cooled return channel for the charging cable inside the vehicle. The hydraulic sensing core 11 is connected to a hydraulic sensor to test the internal liquid pressure of the liquid-cooled pipe 1 and the return pipe 8. The other end is connected to the hydraulic sensing core 11 inside the charging gun head, transmitting data to the integrated circuit of the liquid-cooled charging pile to control the liquid flow rate. This prevents the liquid-cooled pipe 1 and the return pipe 8 from bursting due to excessive pressure. One end of the temperature sensing core 9 is connected to a thermocouple to test the temperature at the connection between the copper conductor 2 and the terminal, as well as the battery. The other end is connected to the temperature sensing core 9 inside the charging gun head, transmitting data to the integrated circuit of the charging pile to control the coolant flow rate and charging speed. The magnitude of the electric current is determined to protect battery safety and the safety of the flame-retardant supercharging cable used inside the new energy vehicle. One end of the liquid level sensing core 10 is connected to the liquid level sensor, and the other end is connected to the liquid level sensing core 10 inside the charging gun head. The data is transmitted to the liquid-cooled pile integrated circuit control board. Its function is to switch to nitrogen gas inside the liquid cooling pipe 1 and switch the return pipe 8 to liquid extraction mode when charging is complete. When the liquid inside the liquid cooling pipe 1 is completely extracted and the integrated circuit board displays a liquid level of zero, the charging gun head and charging port automatically unlock to prevent coolant residue from remaining on the inner wall of the pipe and to prevent liquid from flowing out when the gun head is removed. The enhanced protection filling 12 function is to protect the battery. The return tube 8 is protected from being squeezed and deformed by the copper conductor 2, and all sensor cores are protected from breakage due to vibration and external force. The metal composite wrapping layer 4 provides shielding for the signal transmission of all sensor cores and the transmission of large currents by the copper conductor 2. The metal braided layer 5 provides shielding for the signal transmission of all sensor cores and the transmission of large currents by the copper conductor 2. The flame retardant layer 6 protects the internal cores of the cable. In the event of a vehicle fire during the charging process, there is sufficient time to cut off the charging, extract the coolant from the liquid cooling pipe 1, and unlock and separate the charging gun head from the charging port. The sheath 7 protects the internal structure from external damage and provides flame retardancy.

[0035] 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 which is defined by the appended claims and their equivalents.

Claims

1. A flame-retardant super-fast charging cable for use inside new energy vehicles, comprising a DC+ terminal and a DC- terminal, wherein a reinforced protective filler (12) is provided between the DC+ terminal and the DC- terminal, a metal composite wrapping layer (4) is provided around the DC+ terminal, the DC- terminal and the reinforced protective filler (12), a metal braided layer (5) is provided around the metal composite wrapping layer (4), a flame-retardant layer (6) is provided around the metal braided layer (5), and a sheath (7) is provided around the flame-retardant layer (6), characterized in that: It also includes the fact that the DC+ terminal and the DC- terminal adopt the same structure and are symmetrically arranged; The DC+ terminal and the DC- terminal respectively include a liquid cooling pipe (1) and a return pipe (8) arranged side by side. A copper conductor (2) is provided on the outer periphery of the liquid cooling pipe (1), and an insulating layer (3) is provided on the outer periphery of the copper conductor (2). A hydraulic sensing core (11), a temperature sensing core (9), and a liquid level sensing core (10) are provided on the outer periphery of the return pipe (8).

2. The flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The reinforcing protective filler (12) is made of silicone rubber material with a temperature resistance of -40℃ to 150℃, and the internal reinforcing core is aramid Kevlar.

3. The flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: Both the liquid cooling pipe (1) and the return pipe (8) are made of PA12 tubing. The specifications (outer diameter / inner diameter) of the liquid cooling pipe (1) are φ12 / φ10mm, and the specifications (outer diameter / inner diameter) of the return pipe (8) are φ8 / φ6mm.

4. The flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The copper conductor (2) has a specification of 35mm. 2 The conductor wire diameter is selected as φ0.200±0.003mm.

5. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The insulating layer (3) is made of a low-smoke halogen-free irradiated polyolefin material with a temperature resistance of -40℃ to 150℃.

6. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The hydraulic sensing core (11), the temperature sensing core (9), and the liquid level sensing core (10) all use 0.75mm thick wire. 2 conductor.

7. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The metal composite wrapping layer (4) is made of aluminum-plastic composite strip with a thickness of 0.05 mm and a width of 40 mm.

8. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The metal braided layer (5) is made of tin-plated copper wire with a diameter of φ0.200±0.003mm and a braiding density of 85%-90%.

9. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The flame retardant layer (6) is made of glass fiber tape with a thickness of 0.15 mm and a width of 40 mm.

10. A flame-retardant super-fast charging cable for use inside new energy vehicles according to claim 1, characterized in that: The sheath (7) is made of a low-smoke, halogen-free, radiation-retardant Class A polyolefin material with a temperature resistance of -40℃ to 150℃.

Images