Lightweight new energy automobile charging cable

Abstract

The utility model provides a lightweight new energy automobile charging cable comprising a main body, a conductor arranged in the main body, an insulating layer nested on the outer surface of the conductor, a shielding layer nested on the outer side of the insulating layer, a tensile layer nested on the outer side of the shielding layer, and an outer sheath nested on the outer side of the tensile layer. According to the light-weight new energy automobile charging cable, the outer sheath and other structures are arranged, the outer sheath is made of a thermoplastic polyurethane elastomer material, the cable has the characteristics of wear resistance, weather resistance, oil resistance and flexibility, daily friction, severe weather and oily substance erosion can be resisted, bending damage is avoided, and the service life is prolonged; the hollow structure can deform and absorb energy under the impact of vehicle rolling and the like, and the cambered surface design disperses external force, buffers collision and extrusion for the cable, reduces the damage risk of the internal structure, reduces the maintenance and replacement cost, and guarantees the stable operation of the cable in a complex environment.

Description

Technical Field

[0001] This utility model relates to the field of charging cable technology, and more specifically, to a lightweight charging cable for new energy vehicles. Background Technology

[0002] With the rapid development of new energy vehicles, charging cables, as important components, are of paramount importance in terms of performance and reliability.

[0003] Traditional charging cables are subject to frequent bending, dragging, and pulling during use, which can easily damage their internal structure, affecting charging stability and lifespan. Secondly, they lack effective protection; when run over by vehicles or impacted by external objects, critical components such as the internal conductors and insulation layers are easily damaged, posing safety hazards. Thirdly, they are difficult to adapt to complex outdoor environments; for example, insufficient abrasion resistance leads to surface damage, poor weather resistance causes hardening and softening at extreme temperatures, and weak oil resistance makes them prone to deterioration when in contact with oily substances. In addition, traditional cables are often heavy, which is not conducive to the convenience required for charging new energy vehicles.

[0004] This invention makes the cable more stable during use. Utility Model Content

[0005] The present invention aims to solve the technical problems mentioned in the background art and provide a lightweight charging cable for new energy vehicles.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a lightweight new energy vehicle charging cable, comprising: a main body, wherein a conductor is disposed inside the main body, an insulation layer is nested on the outer surface of the conductor, a shielding layer is nested on the outside of the insulation layer, a tensile layer is nested on the outside of the shielding layer, and an outer sheath is nested on the outside of the tensile layer.

[0007] A further preferred embodiment: the conductor is made of multi-strand stranded silver-plated oxygen-free copper wire.

[0008] A further preferred embodiment: the insulating layer is made of foamed polypropylene material.

[0009] A further preferred embodiment: the shielding layer is a copper braided mesh with a braiding density of 80-90%.

[0010] A further preferred embodiment: the tensile layer comprises multiple aramid fiber braided ropes.

[0011] A further preferred embodiment: the outer sheath is made of thermoplastic polyurethane elastomer material.

[0012] A further preferred embodiment: the conductor stranding pitch is 8-12 mm.

[0013] A further preferred embodiment: the thickness of the insulating layer is 0.3-0.5 mm.

[0014] A further preferred embodiment: a protective block is provided around the outer surface of the main body, the outer side of the protective block is arc-shaped and the inside is hollow.

[0015] Beneficial effects:

[0016] 1. The cable features an outer sheath made of thermoplastic polyurethane elastomer with a thickness of 0.8-1.2mm. Its excellent abrasion resistance effectively resists friction from surfaces such as the ground and corners during daily use. Even under frequent dragging and repeated bending, the sheath surface remains undamaged, protecting the cable's internal structure from external corrosion. Its weather resistance allows it to adapt to various complex outdoor environments. The sheath's physical and chemical properties remain stable, preventing hardening, cracking, softening, or deformation due to temperature changes, ensuring normal cable operation under different climatic conditions. Its oil resistance prevents swelling and deterioration when in contact with oil, lubricants, or other oily substances, effectively extending the cable's lifespan. Furthermore, the sheath's flexibility prevents creases or cracks during bending and winding, maintaining a good shape and greatly improving the cable's ease of use and durability. This provides comprehensive and reliable external protection for the charging cable.

[0017] 2. By incorporating protective blocks, an arc-shaped hollow protective block surrounds the outer surface of the cable body. When the cable is struck by an external object, the protective block absorbs most of the impact force through its own deformation, preventing the impact force from directly acting on the conductor, insulation layer, and other critical structures inside the cable. This effectively reduces the risk of damage to the internal structure. The arc-shaped design further enhances the protective effect, dispersing concentrated external forces evenly when subjected to external forces, reducing the possibility of excessive local stress and further reducing the likelihood of cable damage. In addition, the protective block surrounding the outer surface of the cable body forms a physical barrier, which can buffer collisions and compressions from different directions during daily use, providing all-round protection for the cable, improving cable safety, reducing repair and replacement costs caused by external force damage, and ensuring the stable and reliable operation of new energy vehicle charging cables in complex environments.

[0018] 3. This lightweight new energy vehicle charging cable features an outer sheath made of thermoplastic polyurethane elastomer, which is wear-resistant, weather-resistant, oil-resistant, and flexible. It can withstand daily friction, harsh weather, and oily substances, preventing bending damage and extending service life. The arc-shaped hollow protective block surrounds the cable body. The hollow structure can deform and absorb energy under impact such as being run over by a vehicle, while the arc design disperses external forces. It can also buffer the cable from collisions and compressions in daily life, comprehensively reducing the risk of damage to the internal structure, reducing maintenance and replacement costs, and ensuring stable operation of the cable in complex environments. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0020] Figure 2 This is a schematic diagram of the cross-sectional structure of the cable of this utility model.

[0021] Figure 3 This is a schematic diagram of the connection structure between the conductor and the protective block of this utility model.

[0022] Figure 4 This is a schematic diagram of the protective block structure of this utility model.

[0023] Figure 1-4 In the middle: 1. Main body; 101. Conductor; 102. Insulation layer; 103. Shielding layer; 104. Tensile layer; 105. Outer sheath; 106. Protective block. Detailed Implementation

[0024] The following will refer to the appendix in the embodiments of this utility model. Figures 1-4 The technical solutions in the embodiments of this utility model will be clearly and completely described.

[0025] Please see Figure 1-4 In this embodiment of the present invention, a lightweight new energy vehicle charging cable includes: a main body 1, a conductor 101 disposed inside the main body 1, an insulation layer 102 nested on the outer surface of the conductor 101, a shielding layer 103 nested outside the insulation layer 102, a tensile layer 104 nested outside the shielding layer 103, and an outer sheath 105 nested outside the tensile layer 104; the conductor 101 is made of multi-strand stranded silver-plated oxygen-free copper wire, and the multi-strand stranded structure can improve the flexibility of the cable; a protective block 106 is arranged around the outer surface of the main body 1, the outer side of the protective block 106 is arc-shaped, and the inside is hollow;

[0026] During use, the multi-strand stranded silver-plated oxygen-free copper wire conductor 101, with its high flexibility, adapts to charging scenarios involving frequent bending, reducing the risk of breakage. The silver plating layer enhances conductivity and oxidation resistance, reducing power transmission loss and ensuring high efficiency and stability during high-current fast charging. The insulation layer 102 uses high dielectric strength material to reliably isolate current and ensure electrical safety. The shielding layer 103 effectively resists external electromagnetic interference, maintains stable charging signals, and prevents electromagnetic radiation generated by the cable itself from affecting in-vehicle electronic equipment. The tensile layer 104 enhances the overall tensile strength of the cable, protecting the internal structure from damage during dragging and pulling. The outer sheath 105 provides wear-resistant and weather-resistant protection, extending the cable's service life. The arc-shaped hollow protective block 106 on the outer surface of the main body 1 absorbs energy through hollow structure deformation when run over by a vehicle or impacted by a foreign object, protecting the cable's interior from direct impact. The arc-shaped design disperses external force, further reducing the risk of damage.

[0027] In this embodiment of the invention, the insulation layer 102 is made of foamed polypropylene material. Foamed polypropylene material is lightweight, has excellent insulation performance, and good heat resistance. Its internal bubble structure further reduces the weight of the cable while ensuring insulation performance. The shielding layer 103 is a copper braided mesh, which can effectively shield external electromagnetic interference and ensure the stability of current transmission during charging. The braiding density of the copper braided mesh is 80-90%. The tensile layer 104 includes multiple aramid fiber braided ropes. Aramid fibers have high strength and low density characteristics. Multiple aramid fiber braided ropes can provide good tensile strength for the cable. The diameter of the braided rope is 0.5-1mm, which provides sufficient tensile strength while effectively controlling weight. The outer sheath 105 is made of thermoplastic polyurethane elastomer material, which has good wear resistance, weather resistance, oil resistance and flexibility. The thickness of the outer sheath 105 is 0.8-1.2mm. The stranding pitch of the conductor 101 is 8-12mm. The appropriate stranding pitch can improve the structural stability of the cable and optimize its conductivity while ensuring the flexibility of the cable. The thickness of the insulation layer 102 is 0.3-0.5mm. The thickness of the insulation layer 102 is controlled to reduce weight while ensuring good insulation effect.

[0028] During operation, the multi-strand stranded silver-plated oxygen-free copper wire conductor 101 is stranded at a pitch of 8-12mm, balancing flexibility and conductivity. The silver plating reduces contact resistance and minimizes power transmission loss. The foamed polypropylene insulation layer 102, with its internal bubble structure, provides excellent insulation performance at a thickness of 0.3-0.5mm while reducing cable weight. Its good heat resistance ensures stable operation in high-temperature environments. The copper braided mesh shielding layer 103 with 80-90% braid density effectively isolates external electromagnetic interference, ensuring stable charging current transmission and preventing impact on in-vehicle electronic equipment. Multiple aramid fibers with a diameter of 0.5-1mm are also included. The woven rope forms a tensile layer 104, which utilizes the high strength and low density of aramid fiber to resist dragging and pulling during daily use, protecting the integrity of the internal structure. The thermoplastic polyurethane elastic outer sheath 105 is 0.8-1.2mm thick and, with its wear-resistant, weather-resistant, oil-resistant, and flexible properties, can cope with complex outdoor environments and extend the cable's service life. The arc-shaped hollow protective block 106 outside the main body 1 absorbs energy and disperses stress through deformation when subjected to external impact, providing all-round protection for the cable. Through material selection and structural optimization, this cable achieves lightweighting while ensuring charging performance, meeting the convenient and efficient charging needs of new energy vehicles.

[0029] Working Principle: Conductor 101 uses multi-strand stranded silver-plated oxygen-free copper wire with an 8-12mm stranding pitch to balance flexibility and conductivity. The silver plating reduces contact resistance, significantly reducing power transmission loss and making it suitable for high-current fast charging. The insulation layer 102, made of foamed polypropylene, with its internal bubble structure, reliably isolates current while reducing cable weight at a thickness of only 0.3-0.5mm. Its excellent heat resistance ensures stable performance in high-temperature environments. The copper braided mesh shielding layer 103, with an 80-90% braid density, acts like an electromagnetic shielding mesh, effectively resisting external electromagnetic interference, ensuring stable charging current transmission, and preventing electromagnetic radiation from the cable itself from interfering with in-vehicle electronic equipment. Tensile layer 104... Composed of multiple aramid fiber braided ropes with a diameter of 0.5-1mm, utilizing the high strength and low density characteristics of aramid fibers, it can withstand dragging and pulling during daily use, preventing damage to the internal structure. The thermoplastic polyurethane elastic outer sheath 105 with a thickness of 0.8-1.2mm has wear-resistant, weather-resistant, oil-resistant, and flexible properties to cope with complex outdoor environments and extend the service life of the cable. The arc-shaped hollow protective block 106 outside the main body 1 absorbs energy through the deformation of the hollow structure when it is run over by a vehicle or hit by a foreign object. The arc surface design disperses the external force, protecting the internal structure of the cable in all directions. All parts work together to achieve lightweight while ensuring charging performance, meeting the convenient and efficient charging needs of new energy vehicles.

Claims

1. A lightweight charging cable for new energy vehicles, comprising: The main body (1) is characterized in that: a conductor (101) is provided inside the main body (1), an insulating layer (102) is nested on the outer surface of the conductor (101), a shielding layer (103) is nested on the outer side of the insulating layer (102), a tensile layer (104) is nested on the outer side of the shielding layer (103), and an outer sheath (105) is nested on the outer side of the tensile layer (104).

2. The lightweight new energy vehicle charging cable according to claim 1, characterized in that: The conductor (101) is made of multi-strand silver-plated oxygen-free copper wire.

3. The lightweight new energy vehicle charging cable according to claim 1, characterized in that: The insulating layer (102) is made of foamed polypropylene material.

4. The lightweight new energy vehicle charging cable according to claim 1, characterized in that: The shielding layer (103) is a copper braided mesh with a braiding density of 80-90%.

5. A lightweight new energy vehicle charging cable according to claim 1, characterized in that: The tensile layer (104) comprises multiple aramid fiber braided ropes.

6. The lightweight new energy vehicle charging cable according to claim 1, characterized in that: The outer sheath (105) is made of thermoplastic polyurethane elastomer material.

7. A lightweight new energy vehicle charging cable according to claim 1, characterized in that: The stranding pitch of the conductor (101) is 8-12 mm.

8. A lightweight new energy vehicle charging cable according to claim 1, characterized in that: The thickness of the insulating layer is 0.3-0.5 mm.

9. A lightweight new energy vehicle charging cable according to claim 1, characterized in that: The outer surface of the main body (1) is surrounded by a protective block (106), the outer side of which is arc-shaped and the interior is hollow.

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