A 300a national standard dc charging interface cable

Abstract

The utility model relates to a cable technical field especially relates to a 300A national standard direct current charging interface cable, including cable body, the cable body includes conductor assembly, filling assembly and sheath subassembly, the long filament non -woven fabric is wound around the conductor assembly outside, and filling assembly sets up between the long filament non -woven fabric and conductor assembly gap place, conductor assembly includes first conductor, second conductor, third conductor and fourth conductor, first conductor is symmetrically set side by side, and second conductor and third conductor set up in first conductor one side, and fourth conductor sets up in first conductor other side and is provided with several, filling assembly is filled polyester string, and it is provided with multiple and does not twist, sheath subassembly sets up in the long filament non -woven fabric outside, and sheath subassembly includes the inner sheath layer and outer sheath layer that set gradually from inside to outside, the utility model has the advantage that when the large current transmission has low heat generation, high insulation, strong shielding, structural stability and long life, satisfies the demand of national standard requirement and complex use scene.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a 300A national standard DC charging interface cable. Background Technology

[0002] With the increasing popularity of electric vehicles, the demand for efficient and reliable DC charging equipment is growing. During high-current DC charging, specialized cables are required to ensure safe and stable power transmission. However, existing cables of this type still have the following shortcomings: First, conductors heat up significantly during high-current transmission, and insufficient temperature resistance of the insulation material easily leads to aging; second, the shielding structure design is rudimentary, making it susceptible to electromagnetic interference during charging, affecting signal transmission stability; third, the overall cable structure lacks compactness, and the distribution of filling materials is unreasonable, leading to structural deformation under bending or vibration conditions, affecting service life; fourth, the sheath protection performance is inadequate, making it difficult to adapt to complex outdoor usage scenarios. Utility Model Content

[0003] To address some of the problems existing in the prior art, this utility model provides a 300A national standard DC charging interface cable. This cable has the advantages of low heat generation, high insulation, strong shielding, stable structure and long life when transmitting high current, meeting the requirements of national standards and complex usage scenarios, and is particularly suitable for electric vehicles and other devices that require high current charging.

[0004] To achieve the above objectives, this utility model provides a 300A national standard DC charging interface cable, comprising a cable body, which includes a conductor assembly, a filler assembly, and a sheath assembly. The conductor assembly is wrapped with a long-filament nonwoven fabric, and the filler assembly is disposed in the gap between the long-filament nonwoven fabric and the conductor assembly. The conductor assembly includes a first conductor, a second conductor, a third conductor, and a fourth conductor. The first conductor is arranged symmetrically side-by-side, and the second and third conductors are disposed on one side of the first conductor. The fourth conductor is disposed on the other side of the first conductor, and there are multiple fourth conductors. The filler assembly is filled with polyester rope, and there are multiple untwisted polyester ropes. The sheath assembly is sleeved on the outside of the long-filament nonwoven fabric and has a double-layer co-extruded structure, including an inner sheath layer and an outer sheath layer arranged sequentially from the inside out.

[0005] In operation, the current is first transmitted through the conductor assembly, which includes a first conductor, a second conductor, a third conductor, and a fourth conductor. Each conductor undertakes a specific current transmission task. An insulating layer is provided on the outside of each conductor to ensure good insulation and heat resistance. The shielding layer effectively reduces electromagnetic interference and improves signal transmission stability. On the outside of the conductor assembly, long-filament nonwoven fabric is tightly wrapped with a wrapping overlap rate of 25% to 35%, providing initial protection and fixation for the conductor assembly. Multiple non-twisted polyester ropes are placed in the gaps between the long-filament nonwoven fabric and the conductor assembly to effectively fill the gaps and enhance the cable's structural stability. On the outside of the long-filament nonwoven fabric, a sheath assembly is fitted with a double-layer co-extruded structure, including an inner sheath layer and an outer sheath layer arranged sequentially from the inside out. Both are made of TPU material, providing the cable with good abrasion resistance, corrosion resistance, and environmental resistance, extending its service life. The outer surface of the outer sheath layer is also sprayed with corresponding model information for easy cable identification and management.

[0006] The beneficial effects of this utility model are as follows: By optimizing the conductor assembly structure, the use of a first conductor, a second conductor, a third conductor, and a fourth conductor combining bulletproof wire and bare copper wire, which are twisted together, significantly improves the high current carrying capacity of the cable, meeting the transmission requirements of 300A high current; each conductor is provided with an insulation layer, which effectively prevents leakage between conductors and between conductors and the external environment, improves high temperature resistance and insulation performance, and ensures the safety and stability of the charging process; the combination of a single-sided aluminum foil layer, a shielding layer, and a thin nylon tape layer of the fourth conductor effectively enhances the anti-electromagnetic interference capability and ensures stable signal transmission; the filling assembly uses multiple untwisted filling polyester ropes, combined with a reasonable wrapping overlap rate of long-filament non-woven fabric, to ensure a compact and stable cable structure and reduce bending deformation; the TPU double-layer co-extruded structure of the sheath assembly gives the cable excellent wear resistance, weather resistance, and mechanical strength, and the model information sprayed on the outer sheath surface is easy to identify, and the overall design meets the requirements of national standards and complex usage scenarios.

[0007] As a further improvement of this utility model, in order to eliminate gaps, avoid the risk of partial discharge, and improve insulation effect and structural stability, the third conductor includes symmetrically arranged third conductor bundles, and the outer side of each third conductor bundle is wrapped with a third conductor insulation layer; the outer end of the third conductor insulation layer is wrapped with a nylon tape, and the gap between the nylon tape and the third conductor insulation layer is filled with polyester rope inside the third conductor.

[0008] As a further improvement of this utility model, in order to improve conductivity and reduce losses, while ensuring insulation, heat resistance and flame retardancy to meet the safety requirements in high-current heating scenarios, the third conductor bundle is made of multiple bare copper wires with a diameter of 0.2mm twisted together in a left-hand direction; the nylon tape is wrapped in a right-hand direction, and the wrapping overlap rate of the nylon tape is 15% to 25%; the insulation layer of the third conductor is made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material.

[0009] As a further improvement of this utility model, in order to effectively reduce electromagnetic interference, improve the stability of signal transmission, and enhance the structural stability of the conductor, the fourth conductor includes a uniformly distributed bundle of multiple fourth conductor wires and a fourth conductor insulation layer wrapped around the outside of the bundle of multiple fourth conductor wires; the outer end of the fourth conductor insulation layer is wrapped with a single-sided aluminum foil layer, and the gap between the single-sided aluminum foil layer and the fourth conductor insulation layer is filled with multiple fourth conductor internally filled polyester ropes; the outside of the single-sided aluminum foil layer is also wrapped with a shielding layer, and the outside of the shielding layer is wrapped with a thin nylon tape layer.

[0010] As a further improvement of this utility model, in order to enhance the tensile strength of the conductor, improve the high-frequency signal transmission performance, and balance mechanical strength and anti-interference ability, the fourth conductor bundle is composed of 930D ​​bulletproof wire and bare copper wire with a diameter of 0.15mm twisted together. The bare copper wire is evenly arranged in a circle around the 930D ​​bulletproof wire, and there are multiple wires. The overlap rate of the single-sided aluminum foil layer and the thin nylon tape layer is 15% to 25%. The shielding layer is made of tin-plated copper wire with a diameter of 0.10mm cross-woven. The insulation layer of the fourth conductor is made of high-density polyethylene insulation material.

[0011] As a further improvement of this utility model, in order to improve the conductivity of the conductor while ensuring good insulation performance and heat resistance, the first conductor includes a first conductor bundle and a first conductor insulation layer wrapped around the outside of the first conductor bundle; the first conductor bundle is made of multiple bare copper wires with a diameter of 0.25mm twisted together, and the first conductor insulation layer is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

[0012] As a further improvement of this utility model, in order to balance current carrying capacity and flexibility, and to be suitable for scenarios where charging interfaces are frequently plugged and unplugged, a high-temperature resistant insulating material is used to improve safety in use; the second conductor includes a second conductor bundle and a second conductor insulation layer wrapped around the outside of the second conductor bundle; the second conductor bundle is made of multiple bare copper wires with a diameter of 0.2mm twisted together, and the second conductor insulation layer is made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material.

[0013] As a further improvement of this utility model, in order to ensure the tightness and stability of the cable's internal structure, and improve its wear resistance, corrosion resistance and environmental resistance, while facilitating cable identification and management, the wrapping overlap rate of the filament nonwoven fabric is 25% to 35%, and both the inner and outer sheath layers are made of TPU material; the outer surface of the outer sheath layer is sprayed with corresponding model information. Attached Figure Description

[0014] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings:

[0015] Figure 1 This is a schematic cross-sectional view of the overall structure of this utility model.

[0016] Figure 2 This is a schematic diagram of the cross-section of the third conductor in this utility model.

[0017] Figure 3 This is a schematic cross-sectional view of the fourth conductor in this utility model.

[0018] Among them, 1 is the first conductor, 11 is the first conductor bundle, 12 is the first conductor insulation layer, 2 is the second conductor, 21 is the second conductor bundle, 22 is the second conductor insulation layer, 3 is the third conductor, 31 is the third conductor bundle, 32 is the third conductor insulation layer, 33 is the third conductor filled with polyester rope, 34 is the nylon tape, 4 is the fourth conductor, 41 is the fourth conductor bundle, 42 is the fourth conductor insulation layer, 43 is the single-sided aluminum foil layer, 44 is the shielding layer, 45 is the thin nylon tape layer, 46 is the fourth conductor filled with polyester rope, 5 is the filled polyester rope, 6 is the filament nonwoven fabric, 7 is the inner sheath layer, and 8 is the outer sheath layer. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solutions in this utility model, the following description is provided in conjunction with the appendix. Figure 1-3 The present invention will be further described below. The following embodiments are only used to illustrate the technical solution of the present invention more clearly, and should not be used to limit the protection scope of the present invention.

[0020] In the description of this utility model, it should be noted that the terms "first", "second", "third", etc. are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0021] like Figure 1-3The cable shown is a 300A standard DC charging interface cable, comprising a cable body, which includes a conductor assembly, a filler assembly, and a sheath assembly. The conductor assembly is wrapped with a long-filament nonwoven fabric 6. The filler assembly is disposed in the gap between the long-filament nonwoven fabric 6 and the conductor assembly. The conductor assembly includes a first conductor 1, a second conductor 2, a third conductor 3, and a fourth conductor 4. The first conductor 1 is arranged symmetrically side-by-side, the second conductor 2 and the third conductor 3 are located on one side of the first conductor 1, and several fourth conductors 4 are located on the other side of the first conductor 1. The filler assembly consists of multiple, untwisted polyester ropes 5. The sheath assembly is fitted over the long-filament nonwoven fabric. On the outside of 6, the sheath assembly has a double-layer co-extruded structure, including an inner sheath layer 7 and an outer sheath layer 8 arranged sequentially from the inside to the outside; the third conductor 3 includes symmetrically arranged third conductor bundles 31, and the outer sides of each third conductor bundle 301 are wrapped with a third conductor insulation layer 32; the outer end of the third conductor insulation layer 32 is wrapped with a nylon tape 34, and the gap between the nylon tape 34 and the third conductor insulation layer 32 is filled with a third conductor inner-filled polyester rope 33; the third conductor bundle 31 is made of multiple bare copper wires with a diameter of 0.2mm twisted together in a left-hand direction; the nylon tape 34 is wrapped in a right-hand direction, and the wrapping overlap rate of the nylon tape 34 is 15% to 25%; the third conductor insulation layer 32 is heated to 125℃. Irradiated crosslinked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material; the fourth conductor 4 includes a uniformly distributed multi-strand fourth conductor bundle 41 and a fourth conductor insulation layer 42 wrapped around the outside of the multi-strand fourth conductor bundle 41; the outer end of the fourth conductor insulation layer 42 is wrapped with a single-sided aluminum foil layer 43, and the gap between the single-sided aluminum foil layer 43 and the fourth conductor insulation layer 42 is filled with multiple fourth conductor internally filled polyester ropes 46; the outside of the single-sided aluminum foil layer 43 is also wrapped with a shielding layer 44, and the outside of the shielding layer 44 is wrapped with a thin nylon tape layer 45; the fourth conductor bundle 41 is composed of 930D ​​bulletproof wire and bare copper wire with a diameter of 0.15mm twisted together, and the bare copper wire is uniformly arranged in a circle around the 930D ​​bulletproof wire, and multiple wires are arranged; the... The overlap rate of the single-sided aluminum foil layer 43 and the thin nylon tape layer 45 is 15% to 25%. The shielding layer 44 is made of tin-plated copper wires with a diameter of 0.10 mm, which are cross-woven. The fourth conductor insulation layer 42 is made of high-density polyethylene insulation material. The first conductor 1 includes a first conductor bundle 11 and a first conductor insulation layer 12 wrapped around the outside of the first conductor bundle 11. The first conductor bundle 11 is made of multiple bare copper wires with a diameter of 0.25 mm twisted together. The first conductor insulation layer 12 is made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material. The second conductor 2 includes a second conductor bundle 21 and a second conductor insulation layer 22 wrapped around the outside of the second conductor bundle 21. The second conductor bundle 21 is made of multiple bare copper wires with a diameter of 0.25 mm twisted together.The second conductor insulation layer 22 is made of 2mm bare copper wire twisted together. It uses 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material. The wrapping overlap rate of the filament nonwoven fabric 6 is 25%–35%. Both the inner sheath layer 7 and the outer sheath layer 8 are made of TPU material. The outer surface of the outer sheath layer 8 is coated with corresponding model information.

[0022] In operation, the current is first transmitted through the conductor assembly, which includes a first conductor 1, a second conductor 2, a third conductor 3, and a fourth conductor 4, each undertaking a specific current transmission task. An insulating layer is provided on the outer side of each conductor to ensure good insulation and heat resistance. The shielding layer effectively reduces electromagnetic interference and improves signal transmission stability. On the outside of the conductor assembly, a long-filament nonwoven fabric 6 is tightly wrapped with a wrapping overlap rate of 25% to 35%, providing initial protection and fixation for the conductor assembly. Multiple polyester ropes 5 are provided to fill the gaps between the long-filament nonwoven fabric 6 and the conductor assembly; these ropes are not twisted, effectively filling the gaps and enhancing the cable's structural stability. On the outside of the long-filament nonwoven fabric 6, a sheath assembly is fitted with a double-layer co-extruded structure, including an inner sheath layer 7 and an outer sheath layer 8 arranged sequentially from the inside out. Both are made of TPU material, providing the cable with good abrasion resistance, corrosion resistance, and environmental resistance. The outer surface of the outer sheath layer 8 is also sprayed with corresponding model information for easy cable identification and management.

[0023] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.

Claims

1. A 300A national standard DC charging interface cable, comprising a cable body, characterized in that: The cable body includes a conductor assembly, a filler assembly, and a sheath assembly. The conductor assembly is wrapped with a filament nonwoven fabric (6) on its outer side. The filler assembly is disposed in the gap between the filament nonwoven fabric (6) and the conductor assembly. The conductor assembly includes a first conductor (1), a second conductor (2), a third conductor (3), and a fourth conductor (4). The first conductor (1) is arranged symmetrically side by side. The second conductor (2) and the third conductor (3) are disposed on one side of the first conductor (1). The fourth conductor (4) is disposed on the other side of the first conductor (1). There are several fourth conductors (4). The filler assembly is a filler polyester rope (5). There are several filler polyester ropes (5) that are not twisted. The sheath assembly is sleeved on the outside of the filament nonwoven fabric (6). The sheath assembly is a double-layer co-extruded structure, including an inner sheath layer (7) and an outer sheath layer (8) arranged sequentially from the inside to the outside.

2. The 300A national standard DC charging interface cable according to claim 1, characterized in that: The third conductor (3) includes symmetrically arranged third conductor bundles (31), and the outer side of each third conductor bundle (31) is wrapped with a third conductor insulation layer (32); the outer end of the third conductor insulation layer (32) is wrapped with a nylon tape (34), and the gap between the nylon tape (34) and the third conductor insulation layer (32) is filled with a third conductor inner filled polyester rope (33).

3. The 300A national standard DC charging interface cable according to claim 2, characterized in that: The third conductor bundle (31) is made of multiple bare copper wires with a diameter of 0.2 mm twisted together in the left direction; the nylon tape (34) is wrapped in the right direction, and the wrapping overlap rate of the nylon tape (34) is 15% to 25%; the third conductor insulation layer (32) is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

4. The 300A national standard DC charging interface cable according to claim 1, characterized in that: The fourth conductor (4) includes a uniformly distributed bundle of fourth conductor filaments (41) and a fourth conductor insulation layer (42) wrapped around the outside of the bundle of fourth conductor filaments (41); the outer end of the fourth conductor insulation layer (42) is wrapped with a single-sided aluminum foil layer (43), and the gap between the single-sided aluminum foil layer (43) and the fourth conductor insulation layer (42) is filled with a plurality of fourth conductor inner-filled polyester ropes (46); the outside of the single-sided aluminum foil layer (43) is also wrapped with a shielding layer (44), and the outside of the shielding layer (44) is wrapped with a thin nylon tape layer (45).

5. The 300A national standard DC charging interface cable according to claim 4, characterized in that: The fourth conductor bundle (41) is composed of 930D ​​bulletproof wire and bare copper wire with a diameter of 0.15mm twisted together. The bare copper wire is evenly arranged around the 930D ​​bulletproof wire in a circle, and there are multiple wires. The single-sided aluminum foil layer (43) and the thin nylon tape layer (45) have a wrapping overlap rate of 15% to 25%. The shielding layer (44) is made of tin-plated copper wire with a diameter of 0.10mm cross-woven. The fourth conductor insulation layer (42) is made of high-density polyethylene insulation material.

6. The 300A national standard DC charging interface cable according to claim 1, characterized in that: The first conductor (1) includes a first conductor bundle (11) and a first conductor insulation layer (12) wrapped around the outside of the first conductor bundle (11); the first conductor bundle (11) is made of multiple bare copper wires with a diameter of 0.25 mm twisted together, and the first conductor insulation layer (12) is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

7. The 300A national standard DC charging interface cable according to claim 1, characterized in that: The second conductor (2) includes a second conductor bundle (21) and a second conductor insulation layer (22) wrapped around the outside of the second conductor bundle (21); the second conductor bundle (21) is made of multiple bare copper wires with a diameter of 0.2 mm twisted together, and the second conductor insulation layer (22) is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

8. The 300A national standard DC charging interface cable according to claim 1, characterized in that: The wrapping overlap rate of the long filament nonwoven fabric (6) is 25% to 35%, and both the inner sheath layer (7) and the outer sheath layer (8) are made of TPU material; the outer surface of the outer sheath layer (8) is sprayed with corresponding model information.

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