Liquid-cooled charging cable, charging gun and charging pile

Abstract

The utility model discloses a kind of liquid cooling charging cable, charging gun and charging pile, by including quilt, positive liquid copper tube, negative liquid copper tube, independent pipe and at least one auxiliary cooling pipe, since at least one auxiliary cooling pipe is arranged in the inner cavity of liquid cooling charging cable, and it is in structure respectively with the outer surface of positive liquid copper tube, negative liquid copper tube and independent pipe Contact abutment, to build out multiple path parallel cooling structure, increase the cross-sectional area of cooling liquid flow passage, reduce the flow resistance of liquid cooling gun internal cooling pipe, to improve cooling liquid flow, finally improve liquid cooling heat dissipation effect. That is, in the technical scheme of the application, the auxiliary cooling pipe serves as an independent cooling path (indirect cooling method), and cooperates with the main cooling flow channel (direct cooling method of the positive and negative liquid copper tube). The heat in the high-current channel of the cable can be shared, the unit cross-sectional heat density is effectively reduced, the heat dissipation uniformity is enhanced, and the stability is higher in high-power scenarios.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle charging technology, and in particular to a liquid-cooled charging cable, a charging gun, and a charging pile. Background Technology

[0002] With the rapid development of the new energy electric vehicle market, DC high-power charging has become an important means to improve the user's charging experience. To meet the demands of high-current, high-efficiency charging, liquid-cooled charging gun technology is gradually replacing traditional natural cooling structures and becoming the mainstream trend in the market. Existing liquid-cooled charging guns mainly consist of two parts: liquid-cooled cables and liquid-cooled gun heads. The former connects to the positive and negative copper busbars at the back of the charging pile, while the latter connects to the electric vehicle's charging port. The two are cooled by an internal coolant circuit, thereby achieving a balance between improving current carrying capacity and cable lightweighting and temperature rise control.

[0003] However, in practical applications, liquid-cooled charging guns still face multiple technical bottlenecks. On the one hand, to achieve lightweight and flexible cables, cable structures are increasingly trending towards smaller diameter designs. This leads to two contradictions: firstly, the cross-sectional area of ​​the conductor copper wire decreases, increasing resistance and easily causing an increase in heat generation per unit length; secondly, the diameter of the coolant flow pipe is limited, reducing cooling capacity. When the charging current is further increased to 600A, 800A, or even 1000A, this contradiction between thermal management capability and cable size becomes increasingly prominent, becoming a core obstacle limiting the performance improvement of existing liquid-cooled gun systems. Utility Model Content

[0004] The main objective of this invention is to provide a liquid-cooled charging cable, a charging gun, and a charging station to at least solve the technical problems in the background art.

[0005] To achieve the above objectives, a first aspect of this utility model provides a liquid-cooled charging cable, the liquid-cooled charging cable comprising:

[0006] The protective cover forms an inner cavity;

[0007] A positive electrode liquid-coated copper tube is inserted into the inner cavity to wrap the positive electrode wire and connect it to the input terminal of the cooling system.

[0008] A negative electrode liquid-coated copper tube is inserted into the inner cavity to wrap the negative electrode wire and connect it to the input terminal of the cooling system; wherein, the negative electrode wire and the positive electrode wire are used to conduct current to the charging gun;

[0009] An independent tube, inserted into the inner cavity, is used to transport the coolant transmitted by the cooling system, and is connected to the positive electrode liquid-coated copper tube or the negative electrode liquid-coated copper tube in the charging gun via an adapter;

[0010] At least one auxiliary cooling pipe is inserted into the inner cavity;

[0011] At least one of the auxiliary cooling pipes is in contact with the outer surfaces of the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe in the inner cavity, and is used to dissipate heat from the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe.

[0012] Based on the first aspect, at least one of the auxiliary cooling pipes is inserted into the gap formed in the inner cavity by the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe during the installation process;

[0013] The gap is a non-contact area formed by the staggered arrangement of the positive electrode liquid-coated copper tube, the negative electrode liquid-coated copper tube, and the independent tube.

[0014] Based on the first aspect, the diameter of the auxiliary cooling tube is smaller than the diameter of the positive electrode liquid-coated copper tube, the negative electrode liquid-coated copper tube, and the independent tube, respectively.

[0015] Based on the first aspect, the auxiliary cooling pipe extends into the interior of the charging gun and forms a freely curved section inside;

[0016] The curved portion is used to correspond to the recessed portion provided inside the charging gun.

[0017] Based on the first aspect, thermally conductive silicone grease is filled between the auxiliary cooling tube and the positive electrode liquid-coated copper tube and the negative electrode liquid-coated copper tube, respectively.

[0018] Alternatively, a metal thermally conductive film may be wound between the auxiliary cooling pipe and the positive electrode liquid-coated copper pipe and the negative electrode liquid-coated copper pipe, respectively.

[0019] Based on the first aspect, the auxiliary cooling pipe is arranged inside the housing of the charging gun and does not come into contact with the positive and negative terminals;

[0020] The auxiliary cooling pipe is used to indirectly remove the heat conducted to the internal region of the casing by the positive and negative terminals through the circulation of coolant.

[0021] Based on the first aspect, the auxiliary cooling pipe has the same contact area with the positive electrode liquid-coated copper pipe and the negative electrode liquid-coated copper pipe, respectively.

[0022] Based on the first aspect, the flow direction of the coolant in the auxiliary cooling pipe is opposite to the flow direction of the coolant in the positive electrode liquid-coated copper pipe and / or the negative electrode liquid-coated copper pipe.

[0023] A second aspect of this invention provides a charging gun, comprising a charging gun body and a liquid-cooled charging cable as described in the first aspect.

[0024] A third aspect of this utility model is to provide a charging pile, including a liquid cooling system and a charging gun as described in the second aspect;

[0025] The liquid cooling system includes:

[0026] A water inlet / outlet distributor is used to distribute coolant to the liquid-cooled charging cable;

[0027] A return water separator is used to collect the coolant returning from the charging gun;

[0028] A radiator is used to exchange heat with the returning coolant.

[0029] A fan is used to dissipate heat from the radiator;

[0030] Water tank, used to store coolant and compensate for fluctuations in coolant volume within the system;

[0031] A water pump is used to drive the coolant to circulate in the cooling channel, forming a closed-loop circulation path.

[0032] This utility model discloses a liquid-cooled charging cable, charging gun, and charging pile. By incorporating at least one auxiliary cooling pipe within the inner cavity of the liquid-cooled charging cable, and structurally contacting and abutting the outer surfaces of the positive electrode liquid-coated copper tube, the negative electrode liquid-coated copper tube, and an independent tube, a multi-path parallel cooling structure is constructed. This increases the cross-sectional area of ​​the coolant flow path, reduces the flow resistance of the internal cooling pipes of the liquid-cooling gun, thereby increasing the coolant flow rate and ultimately improving the liquid cooling heat dissipation effect. In other words, in this technical solution, the auxiliary cooling pipe acts as an independent cooling path (indirect heat dissipation), working in conjunction with the main cooling channel (direct heat dissipation via the positive and negative electrode liquid-coated copper tubes). This can share the heat of the high-current channels in the cable, effectively reducing the heat density per unit cross-section, enhancing heat dissipation uniformity, and providing greater stability in high-power scenarios. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of this utility model or related technologies, the drawings used in the description of the embodiments or related technologies 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.

[0034] Figure 1 This is a schematic diagram of the internal structure of the liquid-cooled charging cable provided in the embodiments of this application;

[0035] Figure 2This is a schematic diagram of the auxiliary cooling pipe and protective cover in the embodiments of this application;

[0036] Figure 3 This is a schematic diagram of the structure in which the auxiliary cooling pipe is located inside the charging gun in an embodiment of this application;

[0037] Figure 4 for Figure 3 A schematic diagram of a half-section along section line AA;

[0038] Figure 5 This is a schematic diagram showing the auxiliary cooling pipe and the positive electrode liquid-coated copper pipe being attached (contacting) in an embodiment of this application;

[0039] Figure 6 This is a schematic diagram illustrating the flow relationship between the coolant in the auxiliary cooling pipe and the coolant in the positive electrode copper-clad pipe in this embodiment of the application;

[0040] Figure 7 This is a schematic diagram showing the contact (abutment) between two auxiliary cooling pipes and one positive electrode liquid-coated copper pipe in an embodiment of this application;

[0041] Figure 8 This is a schematic diagram of the structure of a charging pile provided in an embodiment of this application;

[0042] Reference numerals: 1. Liquid-cooled charging cable; 11. Sheath; 12. Positive electrode liquid-coated copper tube; 13. Negative electrode liquid-coated copper tube; 14. Independent tube; 15. Auxiliary cooling tube; 17. Metal thermal conductive film; 18. Gap; 21. Negative electrode liquid-cooled terminal; 22. Positive electrode liquid-cooled terminal; 23. First notch; 24. Second notch; 25. Internal area of ​​the housing; 26. Charging connector; 31. Water inlet water dispenser; 33. Water return water dispenser; 35. Radiator; 34. Fan; 36. Water tank; 37. Water pump; 32. Ball valve; 121. Positive electrode wire; 151. Curved section; 152. Cooling tube; 1511. First arc segment; 1512. Detailed Implementation

[0043] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0044] It should be noted that related terms such as "first" and "second" can be used to describe various components, but these terms do not limit the component. These terms are only used to distinguish one component from another. For example, without departing from the scope of this utility model, the first component can be referred to as the second component, and the second component can similarly be referred to as the first component. The term "and / or" refers to any one or more combinations of related and descriptive terms.

[0045] Please see Figure 1 This application provides a liquid-cooled charging cable 1, which includes a protective sheath 11, a positive electrode liquid-coated copper tube 12, a negative electrode liquid-coated copper tube 13, an independent tube 14, and at least one auxiliary cooling tube 15.

[0046] The following describes the components of liquid-cooled charging cable 1:

[0047] The protective cover 11 serves as the outer covering layer of the liquid-cooled charging cable 1, used to cover multiple functional components inside the cable, and the protective cover 11 forms an inner cavity with accommodating space.

[0048] The positive electrode liquid-coated copper tube 12 is typically a single tube, which passes through the inner cavity formed by the protective sheath 11 to cover the positive electrode wire 121 for current transmission, thereby conducting current to the charging gun 2 through the positive electrode wire. Additionally, one end of the positive electrode liquid-coated copper tube 12 is connected to the inlet (input end) of the cooling system (liquid cooling system), and the other end extends into the charging gun 2 and contacts the positive electrode liquid-cooled terminal, so as to cool the positive electrode liquid-cooled terminal (…) within the charging gun 2 through the formed positive electrode cooling circuit. Figure 3 (22) Cooling and heat dissipation are carried out.

[0049] The negative electrode liquid-coated copper tube 13 is typically a single tube, inserted into the inner cavity formed by the protective sheath 11, used to wrap the negative electrode wire for current transmission, thereby conducting the current to the charging gun 2 through the negative electrode wire. Simultaneously, one end of the negative electrode liquid-coated copper tube 13 is connected to the liquid inlet (input end) of the cooling system, and the other end extends into the charging gun 2 and contacts the negative electrode liquid-cooled terminal, so as to cool the negative electrode liquid-cooled terminal (…) within the charging gun 2 through the formed negative electrode cooling circuit. Figure 3 (21) Cooling and heat dissipation are carried out.

[0050] There are usually two independent tubes 14, one for positive power supply and one for negative power supply. They are respectively installed inside the protective sleeve 11 and are used to transport the coolant from the cooling system. They are connected to the positive liquid-coated copper tube 12 and the negative liquid-coated copper tube 13 via adapters inside the charging gun. In other words, the independent tube 14, the positive liquid-coated copper tube 12, and the negative liquid-coated copper tube 13 together constitute part of the cooling system (coolant circulation).

[0051] The number of auxiliary cooling pipes 15 is at least one, which is set in the inner cavity of the protective cover 11 and has a flexible and deployable structure.

[0052] At least one auxiliary cooling pipe 15 contacts and abuts against the outer surfaces of the positive electrode liquid-coated copper pipe 12, the negative electrode liquid-coated copper pipe 13, and the independent pipe 14 within the inner cavity, and is used to dissipate heat from the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13. That is, the auxiliary cooling pipe 15 forms a multi-point contact heat dissipation path by contacting, abutting, or closely adhering to the outer surfaces of the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13 within the inner cavity. During the flow of the coolant within the cooling pipe 152 of the auxiliary cooling pipe 15, the heat generated by the main conductive path (positive electrode liquid-coated copper pipe 12 and negative electrode liquid-coated copper pipe 13) can be carried away indirectly, thereby enhancing the overall heat dissipation capacity of the cable and avoiding performance degradation, material aging, or cooling system failure caused by local overheating.

[0053] As can be seen, this embodiment of the application constructs a multi-path parallel cooling structure by setting at least one auxiliary cooling pipe 15 in the inner cavity of the liquid-cooled charging cable 1, and making it structurally contact and abut against the outer surfaces of the positive electrode liquid-coated copper pipe 12, the negative electrode liquid-coated copper pipe 13, and the independent pipe 14, respectively. This increases the cross-sectional area of ​​the coolant flow path, reduces the flow resistance of the cooling pipe inside the liquid cooling gun, thereby increasing the coolant flow rate and ultimately improving the liquid cooling heat dissipation effect. That is, in this technical solution, the auxiliary cooling pipe 15, as an independent cooling path (indirect heat dissipation method), works in conjunction with the main cooling channel (direct heat dissipation method of the positive and negative electrode liquid-coated copper pipes), which can share the heat of the high current channel in the cable, effectively reduce the heat density per unit cross-section, enhance heat dissipation uniformity, and is more stable in high-power scenarios.

[0054] In an optional embodiment of this application, at least one auxiliary cooling pipe 15 is inserted into the gap 18 formed in the inner cavity by the positive electrode liquid-coated copper pipe 12, the negative electrode liquid-coated copper pipe 13 and the independent pipe 14 during the laying process.

[0055] Specifically, the gap 18 is a non-contact area formed by the staggered arrangement of the positive electrode liquid-coated copper tube 12, the negative electrode liquid-coated copper tube 13, and the independent tube 14. In other words, the positive electrode liquid-coated copper tube 12, the negative electrode liquid-coated copper tube 13, and the independent tube 14 are arranged asymmetrically within the inner cavity of the sheath 11 to avoid structural congestion caused by the three tubes being completely flush, and to create multiple non-contact areas between them, thus forming the naturally existing structural gap 18. In this embodiment, the auxiliary cooling tube 15 is threaded along this gap 18 in a flexible winding or straight laying manner, so that its outer wall forms a multi-point or continuous contact structure with the outer surfaces of the positive electrode liquid-coated copper tube 12, the negative electrode liquid-coated copper tube 13, and the independent tube 14. This arrangement not only effectively utilizes the limited space inside the cable but also increases the thermal contact area between the auxiliary cooling tube 15 and the main heating element, improving heat exchange efficiency.

[0056] It should be noted that the diameter of the auxiliary cooling pipe 15 is smaller than that of the positive electrode liquid-coated copper pipe 12, the negative electrode liquid-coated copper pipe 13, and the independent pipe 14, respectively. That is, by controlling the size parameters of the auxiliary cooling pipe 15 to be smaller than those of the other main body channels, it can be flexibly inserted into the gap area formed between the main body channels, and achieve multi-point contact with each main body without interfering with the layout of the main conductive path, thereby constructing an effective auxiliary heat dissipation path.

[0057] Please see Figure 2 , Figure 3 and Figure 4 The auxiliary cooling pipe 15 extends into the interior of the charging gun 2 and forms a freely curved section 151 inside. This curved section 151 is used to correspond to the recessed sections (23, 24) provided inside the charging gun 2.

[0058] Specifically, the auxiliary cooling pipe 15 is a continuous flexible tube without any joints or connecting devices in the middle. It can be directly connected to the gun head by a cable, forming a reciprocating path for the coolant, thus avoiding the risk of leakage due to poor sealing of the joints. In addition, the inner diameter of the recessed part is slightly larger than the outer diameter of the auxiliary cooling pipe 15, so that the auxiliary cooling pipe 15 will not collapse even when the internal space of the charging gun 2 is insufficient.

[0059] In an optional embodiment of this application, the first arc segment 1511 and the second arc segment 1512 disposed opposite to each other on the curved portion 151 correspond to the two sides disposed opposite to each other on the recess portion.

[0060] For example, when the recess includes a first recess 23 and a second recess 24 extending outward along the outer shell of the charging gun 2, the first arc segment 1511 is provided at the first recess 23, and the second arc segment 1512 is provided at the second recess.

[0061] It should be noted that, due to the small internal space of the charging gun 2, when the bending radius of the auxiliary cooling pipe 15 inside the charging gun is less than the minimum bending radius of the auxiliary cooling pipe, the auxiliary cooling pipe 15 will collapse. The flow cross-sectional area of ​​the collapsed cooling pipe is greatly reduced, which seriously affects the flow rate.

[0062] In this embodiment, by installing the corresponding positions of the double arc segments and the double notches, when the internal space of the charging gun 2 is limited and cannot form a sufficient bending radius, the left and right sides of the notch structure can protrude moderately toward the charging gun shell to form an outward expansion (first notch 23, second notch 24) to provide a larger curvature buffer zone. This ensures that the minimum bending radius requirement of the double arc segments (first arc segment 1511, second arc segment 1512) in the auxiliary cooling pipe 15 is met during the folding process, effectively avoiding the phenomenon of denting and sudden drop in cooling flow caused by excessive bending.

[0063] Please continue reading. Figure 4 The auxiliary cooling pipe 15 is arranged in the internal area 25 of the housing of the charging gun 2 and does not come into contact with the positive liquid cooling terminal 22 and the negative liquid cooling terminal 21.

[0064] It should be noted that the positive liquid-cooled terminal 22 and the negative liquid-cooled terminal 21 in the charging gun 2 constitute high-voltage positive and negative conductive interfaces, respectively, and each has an integrated coolant flow chamber. The coolant from the positive liquid-coated copper tube 12 and the negative liquid-coated copper tube 13 flows into this chamber to form a closed loop, creating a heat dissipation path for the liquid-cooled terminals. Specifically, one end of each liquid-cooled terminal is electrically connected to the corresponding positive or negative wire, and the other end is inserted into the electric vehicle charging port as an output terminal. That is, the liquid-cooled terminal also serves as a power supply terminal to supply power to external devices connected to the charging connector 26 of the charging gun.

[0065] Specifically, in this embodiment, the auxiliary cooling pipe 15 is arranged in the internal region 25 of the charging gun 2's housing. Based on the circulation of the internal coolant, it indirectly dissipates heat from the internal region 25 of the charging gun 2's housing and the housing material (such as a plastic shell or metal frame) through heat conduction from the terminals (positive liquid-cooled terminal 22 and negative liquid-cooled terminal 21) via heat dissipation (without direct contact with the liquid-cooled terminals). In simpler terms, when the positive and negative liquid-cooled terminals generate heat inside the charging gun 2 during high-current charging, this heat can be transferred to the internal region 25 of the charging gun 2's housing through radiation and conduction. The auxiliary cooling pipe 15 distributed in this region then absorbs and exchanges this heat, thus achieving auxiliary heat dissipation without contacting the conductor body.

[0066] Please see Figure 5The auxiliary cooling pipe 15 is filled with thermally conductive silicone grease between itself and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13; or, a metal thermally conductive film 17 is wound between itself and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13.

[0067] Specifically, to improve the thermal contact efficiency between the auxiliary cooling pipe 15 and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13, and to avoid insufficient heat exchange capacity due to the limited contact area of ​​the actual structure, two preferred thermal conductivity enhancement structures are provided. One method involves filling the contact gap between the auxiliary cooling pipe 15 and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13 with thermally conductive silicone grease. This thermally conductive silicone grease has good thermal conductivity and flexible filling capability, and can effectively fill tiny gaps without changing the pipe structure, reducing contact thermal resistance and enhancing the continuity of the heat flow path. The other method involves winding a metal thermally conductive film 17 between the outer wall of the auxiliary cooling pipe 15 and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13. This metal thermally conductive film 17 can be made of high thermal conductivity materials such as copper foil or aluminum foil. Its structure is thin and flexible with high adhesion, which can expand the actual heat exchange area and improve the indirect heat dissipation effect of the auxiliary cooling pipe 15 on the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13.

[0068] Please see Figure 6 The flow direction of the coolant in the auxiliary cooling pipe 15 is opposite to the flow direction of the coolant in the positive electrode liquid-coated copper pipe 12 and / or the negative electrode liquid-coated copper pipe 13.

[0069] Specifically, when the coolant in the main cooling circuit (composed of the positive electrode liquid-coated copper tube 12 and the negative electrode liquid-coated copper tube 13) flows from the end of the cable to the charging gun 2, the coolant in the auxiliary cooling tube 15 flows back from the gun head area towards the end of the cable. The two flow in opposite directions along their length, forming a reverse cooling flow path. This reverse cooling flow path can create a high-low temperature misalignment distribution in the cross-section, forming a temperature difference cancellation mechanism in the cooling area, which can counteract the uneven temperature caused by the excessive length of the liquid-cooled cable.

[0070] In an optional embodiment of this application, the auxiliary cooling pipe 15 has the same contact area with the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13, respectively.

[0071] Specifically, the outer wall of the auxiliary cooling pipe 15 is symmetrically attached to the side surfaces of the positive and negative electrode liquid-coated copper pipes in a structural layout. This equal contact area allows the auxiliary cooling pipe 15 to provide a balanced heat exchange path to the two main heat sources—the positive electrode wire channel and the negative electrode wire channel—during the cooling process, thereby avoiding temperature deviations caused by differences in local heat exchange efficiency.

[0072] Furthermore, there are multiple possible combinations and arrangements between the auxiliary cooling pipe 15 and the positive electrode liquid-coated copper pipe 12 and the negative electrode liquid-coated copper pipe 13, allowing one auxiliary cooling pipe 15 to contact one liquid-coated copper pipe (e.g., Figure 6 (As shown), or two auxiliary cooling pipes 15 can contact a liquid-coated copper pipe (such as...). Figure 7 As shown in the diagram, one auxiliary cooling pipe can also contact two liquid-coated copper pipes. However, regardless of the mode used, the cross-sectional area of ​​the auxiliary cooling pipes that the positive and negative liquid-coated copper pipes contact should be the same to ensure uniform temperature between the positive and negative copper wires.

[0073] This application also provides a charging gun 2, including a charging gun body and a liquid-cooled charging cable 1 as described in the above embodiments.

[0074] Please see Figure 8 This application also provides a charging pile, including a liquid cooling system and a charging gun 2 as described in the above embodiments.

[0075] The liquid cooling system includes an inlet water inlet water inlet unit 31, a return water inlet unit 33, a radiator 35, a fan 34, a water tank 36, a water pump 37, and a ball valve 32. Specifically, the liquid cooling system is a closed-loop circulation system, and the internal coolant passes through the following components in sequence to form a complete thermal management circulation loop:

[0076] The water tank 36 serves as the system's coolant storage device, storing coolant and compensating for coolant capacity fluctuations within the system. It also compensates for coolant evaporation, leakage, or circulation fluctuations, ensuring a stable coolant supply. The water pump 37 drives the coolant to circulate within the cooling channels, forming a closed-loop circulation path. The inlet water distributor 31 distributes the coolant to the liquid-cooled charging cable 1, distributing the coolant output from the water pump to each cooling branch, guiding it into the positive electrode liquid-coated copper tube, negative electrode liquid-coated copper tube, independent tube, and at least one auxiliary cooling tube within the liquid-cooled charging cable. Multiple ball valves 32 are installed at the output end of the inlet water distributor 31 in each cooling branch, used for manual or automatic adjustment of the coolant flow rate in each branch, achieving cooling equalization or emergency shut-off functions. These ball valves can be manually or automatically controlled, enabling both cooling temperature equalization control and emergency shut-off in case of leaks or other abnormalities. The return water distributor 33 collects the coolant returning from the charging gun 2 and directs it to the heat dissipation unit of the cooling system. The radiator 35 is used to perform heat exchange on the returning coolant, releasing the heat it carries to the external environment. The fan 34 is used to assist the radiator 35 in heat dissipation, improving heat exchange efficiency through forced convection, accelerating the cooling process of the coolant, and ensuring that it has good heat absorption capacity before recirculation.

[0077] In this embodiment, the auxiliary cooling pipe 15 in the charging pile, in addition to its regular temperature equalization and auxiliary cooling functions, also has the ability to maintain degraded system operation after a leak in the main cooling path. When a leak occurs in the positive and negative liquid-filled copper pipes or independent pipes inside the charging gun 2, the user can close the corresponding manual ball valve and simultaneously adjust the manual ball valve 32 corresponding to the auxiliary cooling pipe 15 to its maximum opening to cut off the leakage path and prevent further coolant loss, thereby switching to a degraded mode where the auxiliary cooling pipe undertakes the main cooling task.

[0078] In addition, to enhance cooling capacity in this mode, the auxiliary cooling pipe 15 preferably adopts a smaller diameter and thinner wall design to improve pressure resistance and coolant flow rate. During degraded operation, the system can be calibrated in the laboratory to set a reasonable maximum charging current, for example, by adjusting the water pump pressure to 1.6 MPa and gradually testing the temperature rise to ensure that the temperature rise of the liquid-coated copper pipe and its connection with the liquid-cooled terminal of the nozzle does not exceed the predetermined safety value, and finally determine the maximum safe charging current (e.g., 300A) in degraded mode.

[0079] It is evident that this design offers superior economy and sustainability compared to the traditional approach of discarding or reverting to natural cooling upon leakage of a liquid-cooled gun. Especially in market scenarios, liquid-cooled cables, due to their structural redundancy, are easier to maintain their integrity, while the auxiliary cooling pipe, as a one-piece molded structure without intermediate joints, exhibits leakage resistance an order of magnitude higher than liquid-coated copper pipes and independent pipes, ensuring long-term operational stability.

[0080] Furthermore, to address the issue of uneven temperature rise at the positive and negative terminals caused by long-term use or component wear, this system can achieve flow rate calibration by adjusting the opening of the manual ball valves corresponding to each cooling channel, thus realizing balanced thermal field management. This method is applicable both to laboratory factory calibration during production and to on-site maintenance and adjustment after equipment operation.

[0081] In summary, the liquid-cooled charging cable, charging gun, and charging pile of this application embodiment construct a multi-path parallel cooling structure by setting at least one auxiliary cooling pipe in the inner cavity of the liquid-cooled charging cable and structurally contacting and abutting the outer surfaces of the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe, and the independent pipe, respectively. This increases the cross-sectional area of ​​the coolant flow path, reduces the flow resistance of the cooling pipe inside the liquid-cooling gun, thereby increasing the coolant flow rate and ultimately improving the liquid cooling heat dissipation effect. That is, in this technical solution, the auxiliary cooling pipe, as an independent cooling path (indirect heat dissipation method), works in conjunction with the main cooling channel (direct heat dissipation method of the positive and negative electrode liquid-coated copper pipes), which can share the heat of the high-current channel in the cable, effectively reduce the heat density per unit cross-section, enhance heat dissipation uniformity, and provide greater stability in high-power scenarios.

[0082] In addition, the embodiments of this application also have the following technical effects:

[0083] 1) Based on the auxiliary cooling pipe, the liquid cooling capacity can be increased without increasing the outer diameter of the liquid cooling cable, thereby increasing the maximum current of the liquid-cooled charging gun. For example, the maximum charging current of the charging gun can be increased from 600A to 700A.

[0084] 2) The uniform temperature at both ends of the liquid-cooled cable has a more obvious advantage in long liquid-cooled charging guns, such as 10-meter charging guns, which indirectly increases the maximum charging current of the liquid-cooled charging gun.

[0085] 3) It features adjustable flow rate of coolant inside the auxiliary cooling pipe, resulting in more uniform temperature distribution on the positive and negative copper wires and the corresponding liquid-cooled copper tube outer surfaces. This indirectly increases the maximum charging current of the liquid-cooled charging gun. Calibration can be performed both before and after shipment.

[0086] 4) After leakage of the independent pipe or liquid-coated copper pipe, the auxiliary cooling pipe allows the liquid-cooled charging gun to continue to be used as a liquid-cooled charging gun, which greatly improves the service life of the liquid-cooled charging gun. In this way, the liquid-cooled gun can achieve the same service life as the naturally cooled gun, resulting in lower operating costs for the charging pile and liquid-cooled charging gun, generating higher economic value. Moreover, the operation is simple; the downgrading switch of the liquid-cooled charging gun can be completed simply by closing or opening the corresponding manual ball valve.

[0087] The specific embodiments of the utility model have been described in detail above, but they are only examples, and the utility model is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications or substitutions to the utility model are also within the scope of the utility model. Therefore, all equivalent transformations, modifications, and improvements made without departing from the spirit and principles of the utility model should be covered within the scope of the utility model.

Claims

1. A liquid-cooled charging cable, characterized in that, The liquid-cooled charging cable includes: The protective cover forms an inner cavity; A positive electrode liquid-coated copper tube is inserted into the inner cavity to wrap the positive electrode wire and connect it to the input terminal of the cooling system. A negative electrode liquid-coated copper tube is inserted into the inner cavity to wrap the negative electrode wire and connect it to the input terminal of the cooling system; wherein, the negative electrode wire and the positive electrode wire are used to conduct current to the charging gun; An independent tube, inserted into the inner cavity, is used to transport the coolant transmitted by the cooling system, and is connected to the positive electrode liquid-coated copper tube and / or the negative electrode liquid-coated copper tube in the charging gun via an adapter; At least one auxiliary cooling pipe is inserted into the inner cavity; At least one of the auxiliary cooling pipes is in contact with the outer surfaces of the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe in the inner cavity, and is used to dissipate heat from the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe.

2. The liquid-cooled charging cable as described in claim 1, characterized in that, At least one of the auxiliary cooling pipes is inserted into the gap formed in the inner cavity by the positive electrode liquid-coated copper pipe, the negative electrode liquid-coated copper pipe and the independent pipe during the laying process; The gap is a non-contact area formed by the staggered arrangement of the positive electrode liquid-coated copper tube, the negative electrode liquid-coated copper tube, and the independent tube.

3. The liquid-cooled charging cable as described in claim 2, characterized in that, The diameter of the auxiliary cooling tube is smaller than the diameter of the positive electrode liquid-coated copper tube, the negative electrode liquid-coated copper tube, and the independent tube, respectively.

4. The liquid-cooled charging cable as described in claim 2, characterized in that, The auxiliary cooling pipe extends into the interior of the charging gun and forms a freely curved section inside; The curved portion is used to correspond to the recessed portion provided inside the charging gun.

5. The liquid-cooled charging cable as described in claim 2, characterized in that, The auxiliary cooling pipe is filled with thermally conductive silicone grease between itself and the positive electrode liquid-coated copper pipe and the negative electrode liquid-coated copper pipe, respectively. Alternatively, a metal thermally conductive film may be wound between the auxiliary cooling pipe and the positive electrode liquid-coated copper pipe and the negative electrode liquid-coated copper pipe, respectively.

6. The liquid-cooled charging cable as described in claim 2, characterized in that, The auxiliary cooling pipe is located inside the housing of the charging gun and does not come into contact with the positive or negative terminals. The auxiliary cooling pipe is used to indirectly remove the heat conducted to the internal region of the casing by the positive and negative terminals through the circulation of coolant.

7. The liquid-cooled charging cable as described in claim 2, characterized in that, The auxiliary cooling pipe has the same contact area with both the positive electrode liquid-coated copper pipe and the negative electrode liquid-coated copper pipe.

8. The liquid-cooled charging cable as described in claim 2, characterized in that, The flow direction of the coolant in the auxiliary cooling pipe is opposite to the flow direction of the coolant in the positive electrode liquid-coated copper pipe and / or the negative electrode liquid-coated copper pipe.

9. A charging gun, characterized in that, It includes a charging gun body and a liquid-cooled charging cable as described in any one of claims 1 to 8, wherein the charging gun body is used to be adapted to the liquid-cooled charging cable.

10. A charging pile, characterized in that, Includes a liquid cooling system and a charging gun as described in claim 9; The liquid cooling system includes: A water inlet / outlet distributor is used to distribute coolant to the liquid-cooled charging cable; A return water separator is used to collect the coolant returning from the charging gun; A radiator is used to exchange heat with the returning coolant. A fan is used to dissipate heat from the radiator; Water tank, used to store coolant and compensate for fluctuations in coolant volume within the system; A water pump is used to drive the coolant to circulate in the cooling channel, forming a closed-loop circulation path.

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