A megawatt parallel pipe type charging pile cable

Abstract

Provided in the embodiments of the present application is a megawatt parallel pipe type charging pile cable, specifically: the cable comprises a sheath assembly, a main power line, cooling pipes and core wires; wherein the cooling pipes are at least 4 in number; the sheath assembly covers the main power line, the cooling pipes and the core wires; the cooling pipes are arranged in close contact with the sheath assembly, and the cable is centrally provided with the core wires; the cooling pipes are distributed at equal intervals; the main power line comprises positive power lines and negative power lines, and the positive power lines and the negative power lines are arranged in one-to-one correspondence and symmetry; the positive power lines and the corresponding negative power lines are arranged in close contact with different cooling pipes, respectively. The present application adopts a multi-core split design for the main power line comprising positive power lines and negative power lines, each independent core wire is closely attached to the outer wall of the cooling pipe, heat conduction is strengthened through direct contact, and heat is efficiently transferred vertically to the cooling liquid.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle charging piles, and in particular to a megawatt-level parallel-tube charging pile cable. Background Technology

[0002] Megawatt-class charging stations (MCS) refer to charging equipment with charging power reaching the megawatt (MW) level. As an emerging technology, they primarily serve the fast charging of large electric vehicles such as electric trucks and electric buses. While the market size is relatively small, its growth potential is enormous. The megawatt-class charging station market will mainly be concentrated in regions with high electric vehicle penetration rates, such as my country, Europe, and North America. Driven by the global energy revolution, internet revolution, and intelligent revolution, automotive product forms, travel modes, and energy structures are undergoing profound changes. Large electric vehicles such as electric trucks, electric buses, and electric mining trucks have a strong demand for high-power charging, and megawatt-class charging stations can significantly shorten charging time. It is estimated that by 2025, global sales of electric commercial vehicles will account for 5%-10% of total commercial vehicle sales. While new energy vehicles are developing rapidly, excessively long charging times remain an obstacle to their development. Currently, the 60-80kW DC fast chargers commonly used in public areas often require an hour, and considering waiting time, the charging time further increases.

[0003] The existing "megawatt supercharging" charging pile displays the following interface for charging commercial mining trucks: charging voltage 993.2V, charging current 1195.8A, charging power 1.18766MW. In just 3 minutes, 58.979kWh of electricity has been charged, which is close to the charging speed of refueling a gasoline vehicle. This reduces vehicle waiting time and improves operational efficiency.

[0004] However, existing megawatt-level charging cables quickly transfer heat to the cable surface, causing excessive temperature rise. During charging, the charging personnel directly contact the cable surface, and the high temperature can easily cause burns. To achieve the same transmission current, the cable has a large outer diameter, making it difficult for consumers to handle while charging, resulting in a poor user experience and higher costs. Furthermore, the large gaps inside the cable prevent it from being lightweight. Utility Model Content

[0005] In view of the above problems, this utility model is proposed to provide a megawatt-class parallel-tube charging pile cable that overcomes or at least partially solves the above problems:

[0006] A megawatt-level parallel-tube charging pile cable, the cable includes a sheath assembly, a main power line, a cooling pipe, and a core wire; wherein, at least four cooling pipes are provided;

[0007] The sheath assembly covers the main power line, cooling pipe, and core wire; the cooling pipe is disposed against the wall of the sheath assembly, and the core wire is disposed at the center of the cable; the cooling pipes are evenly spaced.

[0008] The main power line includes a positive power line and a negative power line, which are arranged symmetrically and correspond one-to-one; the positive power line and the corresponding negative power line are respectively attached to the wall of different cooling pipes.

[0009] Preferably, the cooling pipe is made of a thermally conductive material.

[0010] Preferably, the sheath assembly includes a sheath layer, a metal strip, and a metal mesh shielding wire, wherein the sheath layer covers the metal mesh shielding wire, and the metal mesh shielding wire covers the metal strip;

[0011] The metal strip covers the main power line and the cooling pipe.

[0012] Preferably, a strap for tensile strength is provided between the sheath layer and the metal mesh shielding wire, and a filament for shielding is provided between the metal strip, the main power line, and the cooling pipe.

[0013] Preferably, the gap between the main power line and the cooling pipe is provided with a filler line to increase the contact area between the core wire and the cooling pipe.

[0014] Preferably, the core wire includes a central protective sleeve and a ground wire, a signal shielding wire, and a signal control wire disposed inside the central protective sleeve; the signal control wire includes at least one wire.

[0015] Preferably, the signal shielding wire includes a first shielding wire and a second shielding wire twisted together with the first shielding wire;

[0016] The first and second shielding wires are wrapped with a signal shielding layer.

[0017] Preferably, the signal shielding layer includes a metal film shield and a metal braided shield;

[0018] The metal braided shielding covers the metal film shielding, and the metal film shielding covers the first shielding wire and the second shielding wire.

[0019] Preferably, there are 4 cooling pipes, 8 positive power lines, and 8 negative power lines.

[0020] The cooling pipe is configured as a quadrilateral, with four positive power lines forming a group around the cooling pipe and four negative power lines forming a group around the cooling pipe; both the positive power lines and the negative power lines are set close to the wall of the cooling pipe.

[0021] Preferably, an auxiliary power line is provided between the positive power line and the negative power line.

[0022] This application specifically includes the following advantages:

[0023] In the embodiments of this application, compared to the prior art where heat is quickly transferred to the cable surface, leading to excessive temperature rise and potential burns during charging as the user directly contacts the cable surface; and the large cable diameter for achieving the same transmission current, making it difficult for consumers to handle and resulting in a poor user experience and higher cost; and the large internal gaps in the cable preventing weight reduction, this application provides a solution that uses a multi-splitting design for the main power lines (DC+ and DC-), ensuring each core wire is flush against the cooling pipe wall. This allows for optimal vertical heat transfer by the liquid inside the pipe, while also making the cable arrangement more compact. This invention further reduces the outer diameter of the finished product, achieving a lightweight solution. Specifically, the cable includes a sheath assembly, main power lines, cooling pipes, and core wires. At least four cooling pipes are provided. The sheath assembly covers the main power lines, cooling pipes, and core wires. The cooling pipes are mounted against the wall of the sheath assembly, and the core wire is positioned at the center of the cable. The cooling pipes are evenly spaced. The main power lines include positive power lines and negative power lines, which are symmetrically arranged and correspond one-to-one. Each positive power line and its corresponding negative power line are mounted against the wall of a different cooling pipe. This application uses a multi-core, split design for the main power lines, including positive and negative power lines. Each independent core wire is tightly attached to the outer wall of the cooling pipe, enhancing heat conduction through direct contact and achieving efficient longitudinal heat transfer to the coolant. The compact core wire arrangement optimizes space utilization, significantly reducing the overall outer diameter of the cable while also reducing weight. This structure ensures balanced current distribution through current equalization design, combining highly thermally conductive insulating materials with flexible conductors to balance electrical performance and heat dissipation efficiency, ultimately achieving the goal of lightweight design at high power density. The cooling pipes, main power lines, and inner cable surface are all attached to the wall, allowing for better longitudinal heat transfer and lateral heat dissipation. Several liquid-cooled pipes are embedded within the cable, with each positive and negative power line in close proximity to one of them. The liquid-cooled pipes are tangential to the inner cable wall, and the liquid in the pipes carries away the heat released by the power lines longitudinally. Simultaneously, the shielding strip around the cooling pipes and the main cable core prevents the heat from the internal power lines from being transferred laterally to the cable surface. A temperature-equalizing shielding layer is then wrapped around the shielding strip to balance the cable surface temperature, thereby reducing temperature rise and enabling megawatt-level supercharging. Attached Figure Description

[0024] To more clearly illustrate the technical solution of this application, the drawings used in the description of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the main power line of a megawatt-level parallel-tube charging pile cable according to the present invention;

[0026] Figure 2 This is a schematic diagram of the structure of a megawatt-level parallel-tube charging pile cable according to the present invention;

[0027] Figure 3 This is a schematic diagram of the core wire structure of a megawatt-level parallel-tube charging pile cable according to the present invention;

[0028] Figure 4 This is a schematic diagram of the structure of a megawatt-level parallel-tube charging pile cable according to the present invention;

[0029] 1. Sheath layer; 2. Wrapping tape; 3. Filaments; 4. Metal strip; 5. Winding wire; 6. Cooling pipe; 7. Main power line; 71. Positive power line; 72. Negative power line; 8. Cotton thread; 9. Auxiliary power line; 10. Core wire; 101. Ground wire; 102. Signal shielding wire; 103. Signal control line; 11. Flexible filler material. Detailed Implementation

[0030] To make the objectives, features, and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0031] The inventors discovered through analysis of existing technologies that: Megawatt-level charging stations (MCS) refer to charging equipment with charging power reaching the megawatt (MW) level. As an emerging technology, it mainly serves the fast charging of large electric vehicles such as electric trucks and electric buses. The market size is relatively small, but the growth potential is huge. The megawatt-level charging station market will be mainly concentrated in regions with high electric vehicle penetration rates, such as my country, Europe, and North America.

[0032] Driven by the global energy revolution, internet revolution, and intelligent revolution, the form of automobiles, modes of transportation, and energy structure are undergoing profound changes. Large electric vehicles such as electric trucks, electric buses, and electric mining trucks have a strong demand for high-power charging, and megawatt-level charging piles can significantly shorten charging time. It is projected that by 2025, global sales of electric commercial vehicles will account for 5%-10% of total commercial vehicle sales.

[0033] While the new energy vehicle industry is developing rapidly, the excessively long charging time remains a significant obstacle. Currently, the 60-80kW DC fast chargers commonly used in public areas often take up to an hour, and this time is further increased when waiting times are considered. Megawatt-level charging technology, however, significantly shortens charging time. Statistics show that the interface of a megawatt-level supercharging station for commercial mining trucks displays a charging voltage of 993.2V, a charging current of 1195.8A, and a charging power of 1.18766MW. In just 3 minutes, 58.979kWh of electricity is charged, a speed approaching that of refueling a gasoline vehicle, reducing vehicle waiting time and improving operational efficiency.

[0034] Existing megawatt-level charging cables have several drawbacks. First, to achieve the same transmission current, the main power conductor needs to be very thick, resulting in a large cable outer diameter. This makes the cable difficult for consumers to handle while charging, leading to a poor user experience and higher costs. Second, while internal heat is dissipated through cooling pipes, it is also quickly transferred to the cable surface, causing excessive temperature rise. During charging, the charging personnel directly contact the cable surface, which can easily cause burns due to the high temperature. Third, the main power conductor is not split, or is split only once, resulting in large gaps inside the cable. These gaps waste a considerable amount of space, making it impossible to reduce the cable's weight.

[0035] In the embodiments of this application, compared to the prior art where heat is quickly transferred to the cable surface, leading to excessive temperature rise and potential burns during charging as the user directly contacts the cable surface; and the large cable diameter for achieving the same transmission current, making it difficult for consumers to handle and resulting in a poor user experience and higher cost; and the large internal gaps in the cable hindering its lightweight design, this application provides a solution that uses a multi-splitting design for the main power lines (DC+ and DC-, where DC+ is the positive DC terminal and DC- is the negative DC terminal), ensuring that each core wire is in close contact with the cooling pipe wall, allowing the liquid inside the pipe to achieve optimal vertical cooling. This solution achieves lightweighting by transferring heat while simultaneously making the cable arrangement compact, further reducing the outer diameter of the finished product. Specifically, the cable includes a sheath assembly, main power lines, cooling pipes, and core wires. At least four cooling pipes are provided. The sheath assembly covers the main power lines, cooling pipes, and core wires. The cooling pipes are mounted flush against the wall of the sheath assembly, and the core wire is positioned at the center of the cable. The cooling pipes are evenly spaced. The main power lines include positive and negative power lines, which are symmetrically arranged and correspond one-to-one. Each positive and corresponding negative power line is mounted flush against a different cooling pipe. This application uses a multi-core, split design for the main power lines, including positive and negative power lines. Each independent core wire is tightly attached to the outer wall of the cooling pipe, enhancing heat conduction through direct contact and achieving efficient longitudinal heat transfer to the coolant. The compact core wire arrangement optimizes space utilization, significantly reducing the overall outer diameter of the cable and lowering its weight. This structure ensures balanced current distribution through current equalization design, combining highly thermally conductive insulating materials with flexible conductors to balance electrical performance and heat dissipation efficiency, ultimately achieving the goal of lightweight design at high power density. The cooling pipes, main power lines, and inner cable surface are all attached to the wall, allowing for better longitudinal heat transfer and lateral heat dissipation. Several liquid-cooled pipes are embedded within the cable, with each positive and negative power line in close proximity to one of them. The liquid-cooled pipes are tangential to the inner cable wall, and the liquid in the pipes carries away the heat released by the power lines longitudinally. Simultaneously, the shielding strip around the cooling pipes and the main cable core prevents the heat from the internal power lines from being transferred laterally to the cable surface. A temperature-equalizing shielding layer is then wrapped around the shielding strip to balance the cable surface temperature, thereby reducing temperature rise and enabling megawatt-level supercharging.

[0036] Reference Figure 1-4The diagram illustrates the structure of the present invention, which may specifically include the following structure: the cable includes a sheath assembly, a main power line 7, a cooling pipe 6, and a core wire 10; wherein, at least four cooling pipes 6 are provided; the sheath assembly covers the main power line 7, the cooling pipes 6, and the core wire 10; the cooling pipes 6 are disposed against the wall of the sheath assembly, and the core wire 10 is disposed at the center of the cable; the cooling pipes 6 are evenly spaced; the main power line 7 includes a positive power line 71 and a negative power line 72, the positive power line 71 and the negative power line 72 are one-to-one corresponding and symmetrically arranged; the positive power line 71 and the corresponding negative power line 72 are respectively disposed against the wall of different cooling pipes 6.

[0037] In this embodiment, the core wire 10 includes a central protective sleeve and a ground wire 101, a signal shielding wire 102, and a signal control wire 103 disposed inside the central protective sleeve; the signal control wire 103 includes at least one. The signal shielding wire 102 includes a first shielding wire and a second shielding wire twisted together with the first shielding wire; the first shielding wire and the second shielding wire are wrapped with a signal shielding layer.

[0038] As an example, a signal control line 103 is also provided outside the core wire 10, that is, there is at least one signal control line 103 near the main power line 7.

[0039] As an example, the core wire 10 adopts a multi-layer composite structure design. The central protective sleeve integrates a ground wire 101, a signal shield wire 102, and a signal control wire 103, ensuring synergistic optimization of function and safety. The ground wire 101, acting as a protective grounding wire, directly connects the charging pile's metal casing to the power grid's grounding electrode. In the event of leakage or insulation faults, it forms a low-resistance path, conducting the fault current to the ground, effectively preventing the risk of electric shock and equipment damage. At least one signal control wire 103 is provided; in this example, four independent wires are used, each undertaking different functions such as data exchange, status monitoring, and charging control. High-precision signal transmission ensures the safety and communication reliability of the charging process while supporting efficient energy management.

[0040] In this embodiment, the signal shielding layer includes a metal film shield and a metal braided shield; the metal braided shield covers the metal film shield, and the metal film shield covers the first shielding wire and the second shielding wire.

[0041] As an example, the metal film shield is an aluminum foil shield, and the metal braided shield is a copper wire braided shield. The first shielding wire and the second shielding wire are twisted in pairs and then wrapped around the aluminum foil shield and the copper wire braided shield.

[0042] In one specific embodiment, the signal shielding line 102 is composed of a first shielding line and a second shielding line twisted together, employing a twisted-pair structure to suppress common-mode interference. It is externally wrapped with a metal film shield and a metal braided shield, providing dual protection. The metal film shield, such as aluminum foil, tightly wraps the twisted wire pairs, achieving 100% coverage to block high-frequency electromagnetic interference; the metal braided shield, such as copper wire mesh superimposed on the outer layer of aluminum foil, provides mechanical protection and further enhances low-frequency anti-interference capabilities. This layered shielding design significantly reduces signal transmission loss, ensuring the stability and noise immunity of charging communication.

[0043] In one specific embodiment, the first and second shielding wires are arranged in pairs with twisted twists, and the aluminum foil shielding layer is spirally wound along the twisting direction to ensure gapless coverage; the copper wire braided shielding is wrapped with aluminum foil using a high-density braiding process to form a flexible and bend-resistant shield. The ground wire 101 uses a high-conductivity copper core with a cross-sectional area that meets safety specifications and is insulated from the shielding layer and control lines. The signal control line 103 preferably uses a tin-plated copper conductor and is wrapped with a high-temperature resistant insulation layer, with a compact overall arrangement to save space.

[0044] In one specific embodiment, the ground wire 101 is a protective ground wire 101, which is a grounding electrode that directly connects the metal shell of the charging pile to the power grid. When the equipment experiences leakage or insulation failure, the current is conducted to the ground through this wire to prevent leakage to the human body and damage to the equipment.

[0045] As an example, the signal control line 103 is a signal line or control line, which is a key component to ensure safe, efficient, and reliable communication during the charging process, and is used for data exchange, status monitoring, and charging control. Four signal control lines 103 are arranged within the core wire 10. The signal lines are twisted in pairs or twisted as a whole, which improves the cable's resistance to bending and torsion, reduces the breakage rate, and increases its service life.

[0046] In one specific embodiment, the coordinated layout of the ground wire 101, shielding wire, and control wire ensures both electrical safety and signal integrity. The double shielding structure effectively suppresses high-frequency switching noise and external electromagnetic interference from the charging pile. The central protective sleeve can be made of flame-retardant and tensile-resistant material, integrating the internal wiring harness while providing mechanical protection, ensuring high reliability of the cable under complex operating conditions and meeting the stringent requirements of high-power charging of electric vehicles for lightweight design, safety, and electromagnetic compatibility.

[0047] In the embodiment of the present application, the main power line 7 includes a positive power line 71 and a negative power line 72. Each positive power line 71 has a corresponding negative power line 72, and the positive power line 71 and the corresponding negative power line 72 are symmetrically arranged; the positive power line 71 is arranged in close contact with the cooling pipe 6, and the negative power line 72 corresponding to the positive power line 71 is arranged in close contact with another cooling pipe 6. Four cooling pipes 6 are provided, eight positive power lines 71 are provided, and eight negative power lines 72 are provided; the cooling pipes 6 are arranged in a quadrilateral shape, and every four positive power lines 71 are arranged around the cooling pipe 6 as a group, and every four negative power lines 72 are arranged around the cooling pipe 6 as a group; both the positive power line 71 and the negative power line 72 are arranged in close contact with the cooling pipe 6.

[0048] As an example, there are eight positive power lines 71, which are divided into two groups, with four in each group. Each group of positive power lines 71 surrounds a cooling pipe 6, and each positive power line 71 is arranged in close contact with the cooling pipe 6; the two groups of positive power lines 71 are symmetrically arranged, and the two groups of positive power lines 71 are arranged on one side and surround two cooling pipes 6 respectively, showing a "儿" character distribution. The conductors of the main power line 7 (DC+ and DC-) adopt a multi-split type, so that each core wire 10 is in close contact with the cooling pipe 6, and the liquid in the pipe can achieve the best longitudinal heat transfer effect. At the same time, the cable arrangement is compact, further reducing the outer diameter of the finished product and achieving lightweight.

[0049] There are eight negative power lines 72, which are divided into two groups, with four in each group. Each group of negative power lines 72 surrounds a cooling pipe 6, and each positive power line 71 is arranged in close contact with the cooling pipe 6. The two groups of negative power lines 72 are symmetrically arranged, and the two groups of negative power lines 72 are arranged on one side and surround two cooling pipes 6 respectively, showing a "儿" character distribution.

[0050] In a specific embodiment, the main power line 7 adopts a symmetric distribution design. Eight positive power lines 71 and eight negative power lines 72 are provided respectively, and are arranged around four cooling pipes 6 for efficient heat dissipation layout. The positive power line 71 and the negative power line 72 are paired, and each group of four cables is arranged in close contact around a cooling pipe 6 to ensure that each conductor can achieve the best heat conduction through the cooling pipe 6. The eight positive power lines 71 are divided into two groups, with four in each group, surrounding a cooling pipe 6 in a "儿" character shape and symmetrically distributed. The two groups of positive power lines 71 are respectively in close contact with two cooling pipes 6; the negative power line 72 adopts the same layout, and the remaining two groups of four negative power lines 72 are symmetrically arranged around the other two cooling pipes 6. This design makes the positive and negative power lines 72 completely symmetric in space through the balanced distribution of the four quadrilateral cooling pipes 6, which not only optimizes the electromagnetic balance of the current loop, but also significantly improves the overall heat dissipation efficiency through the wall-mounted heat dissipation structure.

[0051] In one specific embodiment, the cooling pipe 6 adopts a quadrilateral cross-section design, with four positive power lines 71 or four negative power lines 72 tightly surrounding each cooling pipe 6. The conductors are in direct contact with the wall of the cooling pipe 6, maximizing the heat exchange area. The positive and negative power lines 72 are located on both sides of the cable, forming a mirror-symmetrical "E" shape, ensuring that the magnetic fields of the current path cancel each other out and reducing eddy current losses. All power lines use high-purity annealed copper conductors and are wrapped with a high thermal conductivity insulation layer to further enhance longitudinal heat dissipation. This layout not only achieves a compact arrangement to reduce the cable's outer diameter, but also, through the symmetrical cooling pipes 6 and power lines, meets the temperature rise requirements of high current transmission while maintaining a lightweight design, making it suitable for high power density charging scenarios.

[0052] In this embodiment of the application, an auxiliary power line 9 is provided between the positive power line 71 and the negative power line 72. This auxiliary power line 9 is a conductor used to supply power to the communication, control signals or low-voltage equipment between the charging pile and the electric vehicle. The auxiliary power line 9 is disposed in the gap between the positive power line 71 or the negative power line 72, or in the gap between the positive power line 71 or the negative power line 72.

[0053] In this embodiment, at least four cooling pipes 6 are provided; the cooling pipes 6 are evenly spaced; and the cooling pipes 6 are located at the four corners of a quadrilateral. The positive power line 71 is mounted against the wall of one of the cooling pipes 6, and the negative power line 72 corresponding to the positive power line 71 is mounted against the wall of another cooling pipe 6. The cooling pipes 6 are mounted against the wall of the sheath assembly.

[0054] As an example, the cooling pipe 6 is attached to the wall along with the main power line 7 and the inner surface of the cable, which not only allows for better longitudinal heat transfer but also lateral heat dissipation. The cooling pipe 6 is made of a thermally conductive material, which greatly improves longitudinal heat transfer. To achieve the same transmission current, the conductor cross-sectional area can be reduced, making the cable lighter and lowering costs. The cooling pipe 6 is made of a high-hardness, high-strength, and high-thermal-conductivity silicone material. Boron nitride is added to the thermally conductive filler, resulting in excellent thermal conductivity and very good stability against water-soluble ethylene glycol mixtures. The conductor cross-sectional area can be reduced; for example, for a transmission current of 1000A, a conventional cooling pipe 6 would require a conductor cross-sectional area of ​​185 mm², while using a thermally conductive material, only 80 mm² is needed. The cooling pipe 6 includes a first cooling, a second cooling, a third cooling, and a fourth cooling, respectively located at the four corners.

[0055] In one specific embodiment, the cooling pipe 6 is made of a high thermal conductivity silicone composite material, filled internally with boron nitride as a thermally conductive filler, giving it excellent longitudinal and lateral heat dissipation capabilities. Four cooling pipes 6 are evenly spaced at the four corners of the quadrilateral, tightly attached to the sheath assembly and in direct contact with the main power line 7, forming an efficient bidirectional heat dissipation path. Different cooling pipes 6 are attached to the positive power line 71 and the corresponding negative power line 72, ensuring the symmetry of the current loop and optimizing electromagnetic compatibility. Due to the high thermal conductivity of the cooling pipes 6, heat can be quickly conducted longitudinally to the coolant. The high hardness and strength of the cooling pipes 6 allow them to maintain structural stability under complex operating conditions, while their excellent resistance to water-glycol mixtures ensures long-term reliability. The tight-fitting design of the main power line 7 and the cooling pipes 6 not only improves heat dissipation efficiency but also makes the internal cable arrangement more compact, further reducing the outer diameter. This structure fully utilizes the thermal conductivity of the cooling pipes 6, significantly reducing the amount of conductor material while ensuring safe current carrying capacity, thus balancing performance and economy.

[0056] In this embodiment of the application, an auxiliary power line 9 is provided between the positive power line 71 and the negative power line 72. The auxiliary power line 9 is a conductor used to supply power for communication, control signals, or low-voltage equipment between the charging pile and the electric vehicle.

[0057] In this embodiment of the application, the gap between the main power line 7 and the cooling pipe 6 is provided with a filler line for increasing the contact area between the core wire 10 and the cooling pipe 6.

[0058] As an example, several filler wires are installed in the gap between the main power line 7 and the cooling pipe 6 inside the cable core. Figure 2 The black dots, such as cotton thread 8, increase the contact area between the main power core wire 10 and the cooling pipe 6, further facilitating a better fit between the main power wire 7 and the pipe, reducing the temperature rise, and improving the current transmission capacity. Inside the cable core, several fillers, such as cotton thread 8 and PP rope, are placed in the gap between the main power wire 7 and the core wire 10. Their function is to increase the contact area between the main power core wire 10 and the cooling pipe 6 through filling, further reducing the temperature rise and improving the current transmission capacity.

[0059] In one specific embodiment, a flexible filler material 11, such as cotton thread 8 or PP rope, is added between the main power line 7 and the cooling pipe 6 inside the cable core. This physical filling eliminates gaps, ensuring a close fit between the conductor and the cooling pipe 6 and effectively increasing the heat conduction contact area. This design not only optimizes the heat dissipation path and reduces interfacial thermal resistance but also compensates for assembly tolerances through the elasticity of the filler material, ensuring tight contact under different operating conditions. Experiments show that the filler structure can reduce the temperature rise of the main power line 7 by 8%-12%, increase the current transmission capacity by more than 10% under the same cross-sectional area, and avoid poor contact caused by vibration, significantly enhancing system reliability. The filler material, such as 130℃-grade PP rope, combines insulation and temperature resistance properties, further ensuring safety during long-term use. Among them, PP rope, which uses polypropylene (PP) rope as the core filling material, has multiple advantages: PP rope has excellent chemical corrosion resistance, low water absorption (<0.01%) and temperature resistance (long-term use from -30℃ to +100℃), and its tensile strength can reach 35-40MPa, which can effectively support the structural stability of the main power line 7 and the cooling pipe 6.

[0060] As an example, the main power line 7 and the cooling pipe 6 are first wrapped with a winding thread before the sheath assembly is wrapped. The winding thread can be nylon thread or the like, and the threads are bundled together first.

[0061] In this embodiment, the sheath assembly includes a sheath layer 1, a metal strip 4, and a metal mesh shielding wire. The sheath layer 1 covers the metal mesh shielding wire, and the metal mesh shielding wire covers the metal strip 4. The metal strip 4 covers the main power line 7 and the cooling pipe 6. A tensile-resistant strap 2 is provided between the sheath layer 1 and the metal mesh shielding wire, and a shielding filament 3 is provided between the metal strip 4, the main power line 7, and the cooling pipe 6.

[0062] As an example, a shielding filament 3, such as Kevlar or nylon wire, is wound around the outside of the stranded cable core, making the cable core more compact and facilitating better fit between the main power line 7 and the tube, reducing temperature rise and improving current transmission capacity. A metal strip 4, not limited to aluminum foil, is placed around the filament 3 around the stranded cable core. Its function is to trap the heat transferred longitudinally during charging within the cable core and transfer it out through the cooling pipe 6, further reducing the surface temperature rise of the cable. A layer of metal mesh shielding wire, such as tinned copper wire or bare copper wire, is placed around the metal strip 4. Its function is to partially shield the cable core from the heat transferred longitudinally during charging. The dissipated heat is evenly distributed, balancing the temperature rise of the cable surface and preventing localized overheating that could harm charging personnel. A wrapping tape 2, such as non-woven fabric, is placed outside the metal mesh shielding wire. Its function is twofold: firstly, to protect the metal mesh shielding wire structure from damage during cable dragging and pulling; secondly, to facilitate the opening of the sheath layer 1 for processing. A sheath layer 1, with a thickness of 2.5mm or more, is placed outside the wrapping tape 2. Its function is twofold: firstly, to protect the cable core; and secondly, to further trap heat inside the cable core, which is then transferred out through the cooling pipe 6, further reducing the temperature rise of the cable surface.

[0063] In one specific embodiment, the sheath assembly adopts a multi-layer composite structure design, consisting of a metal strip 4, a metal mesh shielding wire, a tensile-resistant wrapping tape 2, and a sheath layer 1 from the inside out, forming a stepped heat dissipation and protection system. Kevlar or nylon wire is wound around the outside of the main stranded cable core, ensuring a tight fit between the main power line 7 and the cooling pipe 6, improving heat conduction efficiency and reducing temperature rise. The metal strip 4 (such as aluminum foil) covers the cable core, inhibiting radial heat diffusion and forcing heat to be conducted longitudinally to the cooling pipe 6 for concentrated dissipation. The metal mesh shielding wire (tinned copper wire) covers the outside of the metal strip 4, balancing the surface temperature distribution and preventing localized overheating. The wrapping tape 2 (non-woven fabric) protects the shielding wire structure and facilitates processing. The outermost sheath layer 1 (thickness ≥ 2.5 mm) is made of a high thermal conductivity and flame-retardant material, doubly locking in heat conduction inwards and ensuring that the surface temperature rise meets safety standards.

[0064] In one specific embodiment, this structure achieves precise control of the heat dissipation path through the synergistic effects of filament 3 compressing and optimizing the internal space, metal strip 4 guiding the direction of heat flow, mesh shielding wire uniformly distributing heat, and sheath layer 1 providing insulation. The combination of metal strip 4 and mesh shielding wire not only constrains the longitudinal transfer of heat to cooling pipe 6, but also disperses residual heat through the copper wire mesh, solving the risk of localized surface burns during high-current charging; tensile strength tape 2 enhances mechanical strength, while sheath layer 1 further reduces radial heat loss. Experiments show that under 1000A current carrying conditions, this design can reduce the cable surface temperature rise by more than 15°C, while maintaining a drag bending life of over 50,000 cycles, balancing electrical performance and operational safety.

[0065] like Figure 4In the diagram, 1-8 are DC+, and 9-16 are DC-, which are the main power conductors, split multiple times; 17 is the protective grounding wire 101, which is the grounding electrode that directly connects the metal shell of the charging pile to the power grid. When the equipment has a leakage or insulation fault, the current is conducted to the ground through this wire to prevent leakage to the human body and damage to the equipment; 18-19 are auxiliary power lines 9, which are used to supply power to the communication, control signals or low-voltage equipment between the charging pile and the electric vehicle; 20-21 are signal shielding wires 102, which are twisted in pairs with 20 and 21, and then covered with aluminum foil shielding and copper wire braided shielding; 22-33 are signal or control lines, which are key components to ensure safe, efficient and reliable communication during the charging process, and are used for data exchange, status monitoring and charging control.

[0066] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0067] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0068] The above provides a detailed description of a megawatt-level parallel-tube charging pile cable provided by this utility model. Specific examples have been used to illustrate the principle and implementation of this utility model. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A megawatt level parallel pipe type charging pile cable, characterized in that, The cable comprises a sheath assembly, main power lines, cooling pipes and core wires; wherein the cooling pipes are at least four in number; The sheath assembly covers the main power lines, the cooling pipes and the core wires; the cooling pipes are arranged in close contact with the sheath assembly, and the cable is centrally provided with the core wires; the cooling pipes are distributed at equal intervals; The main power lines comprise positive power lines and negative power lines, which are arranged in one-to-one correspondence and symmetry; the positive power lines and the corresponding negative power lines are arranged in close contact with different cooling pipes, respectively.

2. The megawatt level charging pile cable according to claim 1, characterized in that, The cooling pipes are made of heat-conductive materials.

3. The megawatt level charging pile cable according to claim 1, characterized in that, The sheath assembly comprises a sheath layer, a metal belt and a metal mesh shielding wire; the sheath layer covers the metal mesh shielding wire, and the metal mesh shielding wire covers the metal belt; The metal belt covers the main power lines and the cooling pipes.

4. The megawatt level charging pile cable according to claim 3, characterized in that, A tape for anti-pulling is arranged between the sheath layer and the metal mesh shielding wire, and a filament for shielding is arranged between the metal belt and the main power lines and the cooling pipes.

5. The megawatt-rated charging pile cable according to claim 1, characterized in that, A filling wire for increasing the contact area of the core wires with the cooling pipes is arranged in the gap between the main power lines and the cooling pipes.

6. The megawatt-rated charging pile cable according to claim 1, characterized in that, The core wires comprise a central protective sleeve and a ground wire, a signal shielding wire and a signal control wire arranged inside the central protective sleeve; the signal control wire comprises at least one.

7. The megawatt level charging pile cable according to claim 6, characterized in that, The signal shielding wire comprises a first shielding wire and a second shielding wire twisted with the first shielding wire; The first shielding wire and the second shielding wire are wrapped with a signal shielding layer outside.

8. The megawatt level charging pile cable according to claim 7, characterized in that, The signal shielding layer comprises a metal film shielding and a metal woven shielding; The metal woven shielding covers the metal film shielding, and the metal film shielding covers the first shielding wire and the second shielding wire.

9. The megawatt-rated charging pile cable according to claim 1, characterized in that, The cooling pipes are four in number, the positive power lines are eight in number, and the negative power lines are eight in number; The cooling pipes are arranged in a quadrilateral shape, every four positive power lines are arranged as a group around the cooling pipes, and every four negative power lines are arranged as a group around the cooling pipes; the positive power lines and the negative power lines are arranged in close contact with the cooling pipes.

10. The megawatt-rated charging pile cable according to claim 1, characterized in that, Auxiliary power lines are arranged between the positive power lines and the negative power lines.

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