Power cable for new energy charging pile power supply connection

Abstract

The utility model relates to the field of cables, discloses a power cable for new energy charging pile power supply connection, and effectively solves the problems that a traditional cable sheath is aged and cracked, a signal wire core is easy to break and the like. According to the main scheme, the cable comprises a power wire core group which is composed of at least three power wire cores and at least two auxiliary power wire core conductors, and each conductor is coated with a crosslinked polyethylene XLPE insulating layer; the control wire core group is formed by twisting at least two control wire cores, and each control wire core comprises a sixth-type conductor with a bundle wire compound twisting structure and a thermoplastic elastomer insulating layer coated outside the sixth-type conductor; roundness filling ropes are filled outside the insulating layer, and the insulating layer is coated with a polyphenylene sulfide monofilament braid layer; the shielding layer is composed of a polyester tape wrapping layer and a tinned copper wire braiding layer. An insulating layer is wrapped outside the tinned copper wire braid layer; and the outer sheath is formed by extruding a high-flexibility polyurethane TPU material and coats the outer sides of the power wire core groups and the control wire core groups.

Description

Technical Field

[0001] This utility model relates to the field of cables and provides a power cable for power connection of new energy charging piles. Background Technology

[0002] With the rapid development of new energy vehicles, charging piles, as core infrastructure, directly impact the safety, reliability, and efficiency of the charging process through the performance of their supporting power cables. New energy charging pile cables must meet complex operating conditions, such as withstanding high and low temperature cycles, oil erosion, acid and alkali corrosion, rain immersion, and mechanical wear when exposed to outdoor environments for extended periods. Therefore, existing technologies generally employ multi-core composite cable structures, typically including power cores and signal control cores. The power cores are based on multi-strand soft copper wire stranded conductors, covered with a rubber insulation layer and wrapped with Teflon tape to enhance insulation performance; the signal control cores utilize structures such as tinned copper braided layers to improve signal anti-interference capabilities. Furthermore, the outer layer of the cable often features a waterproof resin coating, a shielding wrapping layer, and a rubber outer sheath to provide waterproofing, electromagnetic shielding, and abrasion resistance.

[0003] However, the aforementioned traditional technologies still have the following significant drawbacks:

[0004] 1. Insufficient weather resistance and mechanical properties of the sheath material: Most mainstream charging cables currently use thermoplastic elastomer (TPE) materials for their outer sheaths. Although these materials have a certain degree of flexibility, they are prone to aging and cracking due to ultraviolet radiation, temperature changes, and mechanical bending during long-term outdoor use. Especially in large-section cables, TPE materials tend to harden and become brittle at low temperatures, increasing the risk of sheath breakage and affecting the overall lifespan and safety of the cable.

[0005] 2. Insufficient reliability of signal core structure: The significant differences in conductor cross-section and insulation layer thickness between the power core and the signal core lead to a mismatch in their interface mechanical properties. Under frequent bending conditions, the signal core is more prone to breakage due to stress concentration, causing communication interruption or control signal failure during charging, thus posing a safety hazard.

[0006] To address the aforementioned issues, existing technologies have attempted to improve the cable by optimizing the sheath formula or adjusting the core layout. However, limitations in material selection and structural design make it difficult to simultaneously achieve high flexibility, aging resistance, and mechanical stability of the signal cores. Therefore, an innovative design is urgently needed to significantly improve the sheath's aging resistance and the signal cores' bending resistance while ensuring electrical performance, in order to meet the increasingly stringent operating requirements of new energy charging pile cables. Utility Model Content

[0007] Based on the above issues.

[0008] To achieve the above objectives, the present invention employs the following technical means:

[0009] A power cable for connecting the power supply of a new energy charging pile, characterized in that it comprises:

[0010] The power conductor assembly consists of at least 3 power conductors and at least 2 auxiliary power conductors, each conductor being covered with a cross-linked polyethylene (XLPE) insulation layer.

[0011] A control conductor assembly, consisting of at least two control conductors twisted together, each control conductor comprising:

[0012] A type 6 conductor with a bundled twisted structure, covered with a thermoplastic elastomer insulation layer;

[0013] The thermoplastic elastomer insulation layer is filled with roundness-enhancing filler rope and covered with a polyphenylene sulfide monofilament (PPS) (3-4) braided layer;

[0014] The shielding layer consists of a polyester tape wrapping layer and a tinned copper wire braided layer;

[0015] The braided tin-plated copper wire is wrapped with an insulating layer.

[0016] The outer sheath is made of highly flexible polyurethane (TPU) material through extrusion molding and covers the outside of the power core group and the control core group.

[0017] In the above scheme, the Class 6 conductor of the control core meets the requirements of Class 6 conductor in CB / T 3956-2008 standard, and the filler rope is made of polyester fiber, the diameter of which matches the edge gap of the thermoplastic elastomer insulation layer to ensure the roundness of the control core.

[0018] In the above scheme, the thickness of the thermoplastic elastomer insulation layer of the control wire core is 0.8mm.

[0019] In the above scheme, the XLPE insulation layer thickness of the power core and auxiliary power core conductor is 1.0-1.4mm, and the cross-sectional area of ​​the power core group is more than 3 times that of the control core group.

[0020] In the above scheme, the TPU material of the outer sheath has a Shore hardness of 75A-90A and a bending radius less than 6 times the outer diameter of the cable.

[0021] In the above scheme, the coverage of the tin-plated copper wire braided layer of the shielding layer is ≥85%, and the braiding density is 60-90 mesh.

[0022] In the above scheme, the cable pitch ratio is 8-12, and the power core group and the control core group are twisted in opposite directions.

[0023] This utility model, through innovative material selection and structural design, effectively solves the technical bottlenecks in weather resistance, mechanical flexibility, and signal stability of new energy charging pile cables, specifically manifested in the following beneficial effects:

[0024] 1. Optimized Overall Performance of the Outer Sheath: The outer sheath is extruded from highly flexible polyurethane (TPU) material, significantly improving its resistance to UV aging and wide temperature range adaptability while maintaining excellent electrical insulation performance. This material system maintains stable physical properties even in extreme temperature environments, effectively avoiding the sheath cracking problems caused by low-temperature embrittlement and high-temperature softening of traditional materials. Simultaneously, its optimized surface abrasion resistance can withstand mechanical wear in outdoor environments.

[0025] 2. Strengthening the core structure: A double-layer stress-resistant shielding structure is formed through the synergistic effect of the polyphenylene sulfide (PPS) braided layer and the tinned copper braided layer. The PPS braided layer effectively disperses bending stress through the high strength of the monofilaments, and together with the electromagnetic shielding function of the tinned copper braided layer, it enhances the core's resistance to bending while ensuring signal transmission integrity, significantly reducing the risk of core breakage under frequent bending conditions.

[0026] 3. Interface Stress Matching Optimization: Through the reverse twisting design and differentiated cross-sectional area configuration of the power core group and the control core group, the mechanical properties of different core groups are complemented. This structural design effectively balances the overall stress distribution of the cable, avoids interface stress concentration caused by differences in conductor rigidity, and thus improves the structural stability of the cable under dynamic bending scenarios.

[0027] 4. Improved Insulation System Reliability: The power conductor uses a cross-linked polyethylene (XLPE) insulation layer, whose optimized dielectric strength and thermal stability can meet the requirements of high current transmission; the control conductor uses a thermoplastic elastomer (TPE) insulation layer, which improves the flexibility of the conductor while ensuring insulation reliability through elastic modulus adjustment. The synergistic effect of the dual insulation system achieves a functional balance between power transmission and signal control.

[0028] 5. Improved Roundness Maintenance Technology: The precise matching design of the control core filler rope and the edge gap of the insulation layer, combined with the unique deformation recovery characteristics of polyester fiber, ensures that the core maintains geometric roundness during bending, effectively preventing the problem of excessive local stress in the insulation layer caused by cross-sectional deformation.

[0029] Through the aforementioned innovative design, this patented technology comprehensively improves the durability and reliability of cables in complex outdoor environments. It is particularly suitable for demanding usage scenarios such as high-frequency plugging and unplugging and large-angle bending of new energy charging piles, and has significant market application value. Attached Figure Description

[0030] Figure 1This is a schematic diagram of the structure of this utility model;

[0031] Figure 2 This is a schematic diagram of the control wire core structure of this utility model. Detailed Implementation

[0032] The embodiments of this utility model will be described in detail below. Although this utility model will be described and illustrated in conjunction with some specific embodiments, it should be noted that this utility model is not limited to these embodiments. On the contrary, any modifications or equivalent substitutions made to this utility model should be covered within the scope of the claims of this utility model.

[0033] Furthermore, to better illustrate this invention, numerous specific details are provided in the following detailed embodiments. Those skilled in the art will understand that this invention can be implemented without these specific details.

[0034] Example 1

[0035] This utility model provides a power cable for connecting the power supply of a new energy charging pile, comprising:

[0036] The power conductor assembly consists of at least 3 power conductors 1 and at least 2 auxiliary power conductors 4, and each conductor is covered with a cross-linked polyethylene (XLPE) insulation layer 2.

[0037] The control wire core assembly is composed of at least two control wire cores 3 twisted together, and each control wire core 3 includes:

[0038] The sixth type conductor 3-1 with a bundled twisted structure is covered with a thermoplastic elastomer insulating layer 3-2;

[0039] The thermoplastic elastomer insulation layer 3-2 is filled with a roundness-enhancing filler rope 3-3, and covered with a polyphenylene sulfide monofilament braided layer 3-4;

[0040] The shielding layer consists of a polyester tape wrapping layer 3-5 and a tinned copper wire braided layer 3-6;

[0041] The tin-plated copper wire braided layer 3-6 is wrapped with an insulating layer 3-7.

[0042] The outer sheath 5 is made of highly flexible polyurethane TPU material and is extruded and molded to cover the outside of the power core group and the control core group.

[0043] In the above scheme, the Class 6 conductor 3-1 of the control core 3 meets the Class 6 conductor requirements of the CB / T 3956-2008 standard, and the filler rope 3-3 is made of polyester fiber, the diameter of which matches the edge gap of the thermoplastic elastomer insulation layer 3-2 to ensure the roundness of the control core.

[0044] In the above scheme, the thermoplastic elastomer insulation layer 3-2 of the control wire core 3 has a thickness of 0.8mm.

[0045] In the above scheme, the thickness of the XLPE insulation layer of the power core 1 and the auxiliary power core conductor 4 is 1.0-1.4mm, and the cross-sectional area of ​​the power core group is more than 3 times that of the control core group.

[0046] In the above scheme, the TPU material of the outer sheath 5 has a Shore hardness of 75A-90A and a bending radius less than 6 times the outer diameter of the cable.

[0047] In the above scheme, the tin-plated copper wire braided layer 3-6 of the shielding layer has a coverage rate of ≥85% and a braiding density of 60-90 mesh.

[0048] In the above scheme, the cable pitch ratio is 8-12, and the power core group and the control core group are twisted in opposite directions.

Claims

1. A power cable for connecting a power supply of a new energy charging pile, characterized in that, include: The power conductor assembly consists of at least 3 power conductors (1) and at least 2 auxiliary power conductors (4), and each conductor is covered with a cross-linked polyethylene XLPE insulation layer (2). The control core assembly is composed of at least two control cores (3) twisted together, each control core (3) comprising: A Class 6 conductor with a bundled twisted structure (3-1) is covered with a thermoplastic elastomer insulation layer (3-2). The thermoplastic elastomer insulation layer (3-2) is filled with roundness filler rope (3-3) and covered with a polyphenylene sulfide monofilament braided layer (3-4); The shielding layer consists of a polyester tape wrapping layer (3-5) and a tinned copper wire braided layer (3-6); The tinned copper wire braided layer (3-6) is wrapped with an insulating layer (3-7). The outer sheath (5) is made of highly flexible polyurethane TPU material and is extruded and molded to cover the outside of the power core group and the control core group.

2. The power cable according to claim 1, characterized in that, The Class 6 conductor (3-1) of the control core (3) meets the Class 6 conductor requirements of the CB / T 3956-2008 standard. The filler rope (3-3) is made of polyester fiber, and its diameter matches the edge gap of the thermoplastic elastomer insulation layer (3-2) to ensure the roundness of the control core.

3. The power cable according to claim 1, characterized in that, The thermoplastic elastomer insulation layer (3-2) of the control core (3) has a thickness of 0.8 mm.

4. The power cable according to claim 1, characterized in that, The thickness of the XLPE insulation layer of the power core (1) and the auxiliary power core conductor (4) is 1.0-1.4 mm, and the cross-sectional area of ​​the power core group is more than 3 times that of the control core group.

5. The power cable according to claim 1, characterized in that, The tin-plated copper wire braided layer (3-6) of the shielding layer has a coverage of ≥85% and a braiding density of 60-90 mesh.

6. The power cable according to any of the claims 1-5, characterized in that, The cable has a pitch ratio of 8-12, and the power core group and the control core group are twisted in opposite directions.

Images