A new energy vehicle charging wire

Abstract

The utility model discloses a novel new energy automobile charging wire, including conductor layer, heat dissipation layer and insulating layer, the conductor layer is by the flattening of the flattening structure of the stranding of multiple annealed soft copper filaments, the heat dissipation layer is covered in the conductor layer outside, by silica gel BN composite material injection moulding, its inside is equipped with the micro -fine ventilation pipeline of through, the insulating layer is located the heat dissipation layer outside, the insulating layer includes inner shielding layer and outer protective layer. The utility model discloses scientific and reasonable structure design, through the flattening structure of conductor layer, compared with traditional circular structure increases the heat dissipation area, solves the problem that the inside of car is narrow because of the section of traditional charging wire and leads to the wiring difficulty of narrow space, the problem of heavy weight, through the inner shielding layer of insulating layer adopts aluminium foil mella composite layer, inhibits the electromagnetic interference of charging wire work, solves the electromagnetic compatibility problem of high -power charging wire.

Description

Technical Field

[0001] This utility model relates to the field of new energy charging cable technology, specifically a new type of new energy vehicle charging cable. Background Technology

[0002] As the charging power of new energy vehicles increases, the charging cables used inside the vehicles are also getting larger to meet the requirements of high current and high voltage, with cross-sections reaching 75mm². 2 The above, even using 150mm 2 The larger the wire cross-section, the more difficult it is to lay cables in the confined space of a vehicle, and it also increases the vehicle's weight. Traditional structures rely on the conductor's own heat dissipation, which can easily lead to overheating and safety hazards under high current. To address this, we propose a new type of charging cable for new energy vehicles. Utility Model Content

[0003] The purpose of this invention is to provide a novel charging cable for new energy vehicles to solve the problems mentioned in the background section.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a novel new energy vehicle charging cable, comprising a conductor layer, a heat dissipation layer, and an insulation layer, wherein the conductor layer is formed by twisting multiple annealed soft copper wires together and then flattening them into a flat structure;

[0005] The heat dissipation layer covers the outside of the conductor layer and is injection molded from silicone BN composite material, with through-hole micro ventilation channels inside.

[0006] The insulating layer is disposed on the outside of the heat dissipation layer, and the insulating layer includes an inner shielding layer and an outer protective layer.

[0007] In the above scheme, graphene nanosheets or aluminum nitride ceramic particles are added to the heat dissipation layer.

[0008] In the above scheme, the flat cross-section of the conductor layer has a wavy or toothed structure, and the surface is provided with uniformly distributed protrusions.

[0009] In the above scheme, the micro ventilation duct has a spiral or branched structure, the inner wall of the duct is provided with flow guiding protrusions, and one end of the micro ventilation duct can be connected to a vehicle cooling device.

[0010] In the above scheme, the inner shielding layer is an aluminum foil Mylar composite layer.

[0011] In the above scheme, the outer side of the heat dissipation layer is provided with metal heat dissipation fins, and the metal heat dissipation fins are connected to the air outlet of the micro ventilation duct.

[0012] In the above scheme, the outer surface of the insulating layer is coated with a self-healing coating.

[0013] Compared with existing technologies, the beneficial effects of this utility model are as follows: This novel new energy vehicle charging cable has a simple and reasonable structural design and strong practicality. The flat structure of the conductor layer increases the heat dissipation area compared to the traditional circular structure, solving the problems of difficult wiring and heavy weight in the narrow space inside the vehicle caused by the large cross-section of traditional charging cables. The inner shielding layer of the insulation layer uses an aluminum foil Mylar composite layer to suppress electromagnetic interference during operation, solving the electromagnetic compatibility problem of high-power charging cables. The micro-ventilation duct enhances airflow efficiency, and connecting it to the vehicle's cooling system further reduces thermal resistance. The metal heat dissipation fins on the outside of the heat dissipation layer connect to the air outlet of the ventilation duct, forming a three-dimensional heat dissipation channel. Combining air cooling and passive cooling further improves heat dissipation efficiency. This solves the problem of insufficient conductor heat dissipation efficiency during high-current charging. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this utility model.

[0015] Figure 2 This is a cross-sectional schematic diagram of the insulating layer structure of this utility model.

[0016] Figure 3 This is a schematic diagram of the internal structure of the heat dissipation layer of this utility model.

[0017] In the diagram: 1. Conductor layer; 2. Heat dissipation layer; 3. Micro-ventilation duct; 4. Insulation layer; 41. Inner shielding layer; 42. Outer protective layer; 5. Metal heat dissipation fins; 6. Self-healing coating. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] Please see Figure 1-3 This utility model provides a technical solution: a new type of new energy vehicle charging cable, including a conductor layer 1, a heat dissipation layer 2 and an insulation layer 4, wherein the conductor layer 1 is formed by twisting multiple annealed soft copper wires together and then flattening them into a flat structure.

[0020] The heat dissipation layer 2 covers the outside of the conductor layer 1 and is injection molded from silicone BN composite material. It has a through-hole micro ventilation channel 3 inside.

[0021] The insulating layer 4 is disposed on the outside of the heat dissipation layer 2, and the insulating layer 4 includes an inner shielding layer 41 and an outer protective layer 42.

[0022] The flat structure of conductor layer 1 makes the charging cable flat overall, increasing the heat dissipation area by 40-50% compared to the traditional circular structure, while reducing the cross-sectional thickness, which facilitates wiring in narrow spaces inside the vehicle and saves installation space.

[0023] The silicone BN composite material of the heat dissipation layer 2 has both flexibility and thermal conductivity, and the internal micro ventilation channels 3 provide channels for subsequent air cooling.

[0024] The insulation layer has a 4-layer design: the inner shielding layer 41 is used for electromagnetic shielding, and the outer protective layer 42 provides physical protection.

[0025] In the above scheme, graphene nanosheets or aluminum nitride ceramic particles are added to the heat dissipation layer 2. Graphene nanosheets or aluminum nitride ceramic particles can improve the thermal conductivity of the heat dissipation layer 2, significantly improving it compared to the original silicone BN composite material, further reducing thermal resistance, and making the 30mm... 2 The conductor current carrying capacity is equivalent to that of a traditional 75mm² conductor. 2 conductor.

[0026] In the above scheme, the flat cross-section of the conductor layer 1 is a wavy or toothed structure, and the surface is provided with uniformly distributed protrusions. The wavy / toothed cross-section and protrusion design further increases the contact area between the conductor surface and the heat dissipation layer 2, and at the same time, the concave and convex structure disrupts the airflow field, enhancing the natural convection heat dissipation effect.

[0027] In the above scheme, the micro-ventilation duct 3 has a spiral or branched structure, with guide protrusions on the inner wall of the duct, and one end of the micro-ventilation duct 3 can be connected to a vehicle-mounted cooling device. The spiral / branched duct design extends the residence time of air in the duct, and the guide protrusions can guide the airflow to be evenly distributed. After connecting to the vehicle-mounted cooling device, forced convection is formed, which further reduces thermal resistance compared to passive cooling.

[0028] In the above scheme, the inner shielding layer 41 is an aluminum foil Mylar composite layer. The aluminum foil Mylar composite layer can effectively shield the electromagnetic radiation generated by the charging cable when it is operating at high current, meet the electromagnetic compatibility requirements of vehicle electronic equipment, and avoid interference with the vehicle control system.

[0029] In the above scheme, the outer side of the heat dissipation layer 2 is provided with metal heat dissipation fins 5, which are connected to the air outlet of the micro-ventilation duct 3. The metal heat dissipation fins 5 increase the exposed heat dissipation area of ​​the heat dissipation layer 2 and form a three-dimensional channel of "air inlet - internal convection - air outlet heat dissipation" with the air outlet of the ventilation duct 3, thereby improving the overall heat dissipation efficiency.

[0030] In the above scheme, the outer surface of the insulating layer 4 is coated with a self-healing coating 6. The self-healing coating 6 is composed of polyurethane elastomer and microcapsule repair agent. When scratches occur on the surface of the insulating layer 4, the microcapsules rupture and release the repair agent, automatically filling the damaged area and improving the durability of the insulating layer.

[0031] Working principle:

[0032] This novel charging cable for new energy vehicles features a conductor layer 1 composed of multiple annealed soft copper wires twisted and flattened to form a flat structure, generating heat when a large current passes through. The flat structure increases the surface area, initially improving heat dissipation efficiency. The silicone BN composite material of the heat dissipation layer 2 rapidly conducts heat from the conductor layer 1, while the wavy conductor surface ensures more thorough contact with the heat dissipation layer, further reducing thermal resistance. The spiral / branched structure within the micro-ventilation duct 3 guides airflow, and the guide protrusions enhance turbulence, forming forced convection after connecting to the vehicle's fan, expelling heat through the air outlet and further diffusing it via the metal heat dissipation fins 5. The inner shielding layer 41 suppresses electromagnetic interference, the outer protective layer 42 provides physical protection, and the self-healing coating 6 automatically repairs surface damage, ensuring long-term reliability of the insulation layer. Through a multi-level heat dissipation design—combining a flat conductor increasing the heat dissipation area, high thermal conductivity materials for rapid heat conduction, forced convection through ventilation ducts, and three-dimensional heat dissipation from metal fins—along with electromagnetic shielding and self-healing protection, the cable achieves the technical effects of high current carrying capacity, lightweight design, and high reliability for a small-section conductor.

[0033] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A novel charging cable for new energy vehicles, comprising a conductor layer (1), a heat dissipation layer (2), and an insulation layer (4), characterized in that: The conductor layer (1) is formed by twisting multiple annealed soft copper wires together and then flattening them into a flat structure; The heat dissipation layer (2) covers the outside of the conductor layer (1) and is injection molded from silicone BN composite material. It has a through-hole micro ventilation channel (3) inside. The insulating layer (4) is disposed on the outside of the heat dissipation layer (2), and the insulating layer (4) includes an inner shielding layer (41) and an outer protective layer (42).

2. The novel new energy vehicle charging cable according to claim 1, characterized in that: The heat dissipation layer (2) contains graphene nanosheets or aluminum nitride ceramic particles.

3. The novel new energy vehicle charging cable according to claim 1, characterized in that: The conductor layer (1) has a flat cross-section with a wavy or toothed structure and uniformly distributed protrusions on its surface.

4. The novel new energy vehicle charging cable according to claim 1, characterized in that: The micro ventilation duct (3) has a spiral or branched structure, and the inner wall of the duct is provided with flow guiding protrusions. One end of the micro ventilation duct (3) can be connected to a vehicle heat dissipation device.

5. A novel new energy vehicle charging cable according to claim 1, characterized in that: The inner shielding layer (41) is an aluminum foil Mylar composite layer.

6. A novel new energy vehicle charging cable according to claim 1, characterized in that: The heat dissipation layer (2) is provided with metal heat dissipation fins (5) on the outside, and the metal heat dissipation fins (5) are connected to the air outlet of the micro ventilation duct (3).

7. A novel new energy vehicle charging cable according to claim 1, characterized in that: The outer surface of the insulating layer (4) is coated with a self-healing coating (6).

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