A 300A national standard DC charging interface cable with multi-diameter composite insulation

Abstract

This utility model relates to the field of cable technology, and in particular to a 300A national standard DC charging interface cable with multi-diameter composite insulation, comprising a conductor assembly and a sheath assembly. The sheath assembly wraps around the outside of the conductor assembly, and a second wrapping layer is provided between the conductor assembly and the sheath assembly. Second and third fillers are provided in the gaps between the second wrapping layer and the conductor assembly, and several of each are provided. The conductor assembly includes a first conductor, a second conductor, a third conductor, and a fourth conductor. The first and third conductors are symmetrically arranged, and several fourth conductors are provided. A first wrapping layer is provided at the outer end of the second and third conductors, and several first fillers are provided in the gaps between the first and third conductors. The sheath assembly includes an inner sheath layer and an outer sheath layer arranged sequentially from the inside out. This utility model, through its multi-diameter conductor design, achieves a perfect combination of high current transmission and multi-functional requirements, improving the versatility and flexibility of the cable.

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 with multi-diameter composite insulation. Background Technology

[0002] Against the backdrop of the rapid development of new energy vehicles, DC charging interface cables, as key components connecting charging facilities and electric vehicles, directly affect charging efficiency and safety. Existing high-current DC charging cables have several shortcomings in practical applications: Firstly, traditional cables often employ a single-diameter conductor structure, making it difficult to balance current-carrying capacity and structural flexibility during high-current transmission. Furthermore, when multiple conductors are combined, differences in conductor diameter can lead to uneven electric field distribution, affecting insulation reliability. Secondly, insulation materials are prone to aging and overheating under long-term high-current operating conditions. Additionally, design flaws in the cable's internal filling and wrapping structures can result in a loose overall structure, insufficient resistance to mechanical forces, and a lack of effective shielding, making them susceptible to electromagnetic interference that affects signal transmission stability. Moreover, the single-layer sheath structure of existing cables is insufficient to meet the long-term usage requirements of high-power charging scenarios in terms of weather resistance, flame retardancy, and anti-aging performance. 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 with multi-diameter composite insulation. Through the multi-diameter conductor design, this cable successfully achieves a perfect combination of high current transmission and multi-functional requirements, significantly improving the cable's versatility and flexibility. It is particularly suitable for electric vehicles and other devices that require high-current charging, meeting the charging needs of high power and high efficiency.

[0004] To achieve the above objectives, this utility model provides a 300A national standard DC charging interface cable with multi-diameter composite insulation, comprising a conductor assembly and a sheath assembly. The sheath assembly wraps around the outside of the conductor assembly, and a second wrapping layer is provided between the conductor assembly and the sheath assembly. A second filler and a third filler are provided in the gap between the second wrapping layer and the conductor assembly, and a plurality of the second filler and the third filler are provided. The conductor assembly includes a first conductor, a second conductor, a third conductor, and a fourth conductor. The first conductor and the third conductor are symmetrically arranged, and a plurality of the fourth conductor are provided. A first wrapping layer is provided at the outer end of the second conductor and the third conductor, and a plurality of first fillers are provided in the gap between the first wrapping layer and the second conductor and the third conductor. The sheath assembly has a double-layer co-extruded structure, comprising an inner sheath layer and an outer sheath layer arranged sequentially from the inside to the outside.

[0005] In operation, the current is transmitted sequentially through a conductor assembly composed of multiple conductors of different diameters. The first conductor is formed by stranding multiple bare copper wires with a diameter of 0.25mm and encased in a first conductor insulation layer made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation. The second conductor is formed by stranding multiple bare copper wires with a diameter of 0.2mm and encased in a second conductor insulation layer of the same material. The third conductor is formed by stranding multiple bare copper wires with a diameter of 0.15mm and encased in a third conductor insulation layer of the same material. The fourth conductor consists of multiple strands of fourth conductor wire, including 930D ​​bulletproof wire, a 0.15mm diameter first bare copper wire, and a second bare copper wire formed by stranding two 0.15mm diameter bare copper wires, and is encased in... The fourth conductor has a high-density polyethylene insulation layer, which ensures stable current transmission. During transmission, the fourth conductor is shielded by a third wrapping layer made of aluminum foil and a fourth wrapping layer made of nylon tape. The shielding layer uses 0.10mm diameter tinned copper wires in a cross-weave pattern to reduce electromagnetic interference. Meanwhile, the first filler, the third filler, and the second filler made of untwisted polyester rope and solid strips filled with mesh tape and fiber filaments, under the wrapping of the first wrapping layer made of nylon tape and the second wrapping layer made of long-filament non-woven fabric, maintain the compactness and stability of the cable's internal structure. Finally, the double-layer co-extruded sheath assembly, consisting of an inner sheath layer and an outer sheath layer made of TPU material, provides abrasion and corrosion resistance protection for the cable, improving the outer layer's protective capability.

[0006] The beneficial effects of this utility model are as follows: The first, second, and third conductors employ a bundle structure of bare copper wires of different diameters twisted together, combined with 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation. This ensures stable transmission of a 300A high current while improving the high-temperature resistance and flame-retardant safety of the insulation layer. The fourth conductor bundle incorporates 930D ​​bulletproof wire and specially arranged bare copper wires, along with a high-density polyethylene insulation layer, aluminum foil and nylon tape wrapping, and a tinned copper wire braided shielding layer. This not only enhances the mechanical strength of the conductor but also effectively suppresses electromagnetic interference through the multi-layer shielding structure, ensuring stable signal transmission. Qualitatively, the non-twisted polyester ropes and solid strips filling the gaps between the conductors, combined with nylon tape and long-filament non-woven fabric wrapping, fill the gaps and enhance the structural compactness, improving the cable's resistance to deformation and heat dissipation performance; the double-layer co-extruded inner and outer sheath layers, combined with TPU material, give the cable excellent weather resistance, abrasion resistance, and flame retardancy; the overall structure, through multi-diameter composite insulation, optimized filling, and shielding design, achieves high reliability, high safety, and long service life under high current transmission, meeting the stringent requirements of national standards for 300A DC charging interface cables, and possesses significant technical advantages and broad market prospects.

[0007] As a further improvement of this utility model, in order to improve the high temperature resistance, flame retardancy and anti-aging performance of the insulation layer while ensuring the high current carrying capacity, 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.

[0008] As a further improvement of this utility model, in order to optimize the electric field distribution of the multi-conductor through differential wire diameter design and enhance insulation reliability, 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.

[0009] As a further improvement of this utility model, in order to achieve a balance between the current carrying capacity and structural flexibility of the multi-conductor through the gradient configuration of wire diameter, the third conductor includes a third conductor bundle and a third conductor insulation layer wrapped around the outside of the third conductor bundle; the third conductor bundle is made of multiple bare copper wires with a diameter of 0.15mm twisted together, and the third conductor insulation layer is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

[0010] As a further improvement of this utility model, in order to enhance the electromagnetic interference resistance and mechanical protection performance of the conductor, the fourth conductor includes multiple strands of fourth conductor bundles and a fourth conductor insulation layer wrapped around the outside of the fourth conductor bundles; a third wrapping layer is provided at the outer end of the fourth conductor insulation layer, and multiple fourth fillers are provided in the gap between the third wrapping layer and the fourth conductor insulation layer; a shielding layer is also wrapped around the outside of the third wrapping layer, and a fourth wrapping layer is provided on the outside of the shielding layer.

[0011] As a further improvement of this utility model, in order to optimize insulation and filling performance, improve electromagnetic shielding effect, and enhance the density and mechanical strength of the wrapping layer; the wrapping overlap rate of the third wrapping layer and the fourth wrapping layer is 15% to 25%, and the third wrapping layer and the fourth wrapping layer are aluminum foil and nylon tape, respectively; the fourth filler is untwisted polyester rope, and the shielding layer is 0.10mm diameter tin-plated copper wire cross-woven; the fourth conductor insulation layer is made of high-density polyethylene insulation material.

[0012] As a further improvement of this utility model, in order to enhance mechanical strength and improve current carrying capacity, the fourth conductor bundle includes a 930D ​​bulletproof wire and a plurality of first bare copper wires evenly arranged in a circle around the 930D ​​bulletproof wire; the diameter of the first bare copper wire is 0.15mm, and a second bare copper wire is also provided between the outermost first bare copper wires, which is formed by twisting two bare copper wires with a diameter of 0.15mm together.

[0013] As a further improvement of this utility model, in order to achieve layered wrapping and structural reinforcement of the conductor assembly, the first wrapping layer is a nylon tape with a wrapping overlap rate of 15% to 25%; the second wrapping layer is a long-filament non-woven fabric with a wrapping overlap rate of 25% to 35%.

[0014] As a further improvement of this utility model, in order to improve the cable structure compactness, flame retardancy and insulation by using differentiated filling materials, the first filler and the third filler are both untwisted polyester ropes, and the second filler is a solid strip; the solid strip is filled with a mesh tape and fiber filaments in the middle, and the solid strip is made of 90℃ low smoke halogen-free flame retardant irradiated cross-linked polyolefin insulation material.

[0015] As a further improvement of this utility model, in order to enhance the outer protective capability of the cable, extend the service life of the cable, and meet the national standard requirements for outdoor use scenarios, both the inner and outer sheath layers are made of TPU material. Attached Figure Description

[0016] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings:

[0017] Figure 1 This is a schematic cross-sectional view of the overall structure of this utility model.

[0018] Figure 2 This is a schematic cross-sectional view of the fourth conductor in this utility model.

[0019] Figure 3 This is a schematic diagram of the cross-sectional arrangement of the fourth conductor bundle in this utility model.

[0020] Among them, 1 is the first conductor, 101 is the first conductor bundle, 102 is the first conductor insulation layer, 2 is the second conductor, 201 is the second conductor bundle, 202 is the second conductor insulation layer, 3 is the third conductor, 301 is the third conductor bundle, 302 is the third conductor insulation layer, 4 is the fourth conductor, 401 is the fourth conductor bundle, 4011 is the 930D ​​bulletproof wire, 4012 is the first bare copper wire, 4013 is the second bare copper wire, 402 is the fourth conductor insulation layer, 403 is the fourth filler, 404 is the third wrapping layer, 405 is the shielding layer, 406 is the fourth wrapping layer, 5 is the first filler, 6 is the first wrapping layer, 7 is the second filler, 8 is the third filler, 9 is the second wrapping layer, 10 is the inner sheath layer, and 11 is the outer sheath layer. Detailed Implementation

[0021] 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.

[0022] 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.

[0023] like Figure 1-3The cable, a 300A standard DC charging interface cable with multi-diameter composite insulation, includes a conductor assembly and a sheath assembly. The sheath assembly wraps around the outside of the conductor assembly, and a second wrapping layer 9 is provided between the conductor assembly and the sheath assembly. Second filler 7 and third filler 8 are provided in the gap between the second wrapping layer 9 and the conductor assembly, and multiple copies of each type are provided. 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 and the third conductor 3 are symmetrically arranged, and multiple copies of the fourth conductor 4 are provided. A first wrapping layer 6 is provided at the outer end of the second conductor 2 and the third conductor 3, and a second wrapping layer 6 is provided in the gap between the first wrapping layer 6 and the second conductor 2 and the third conductor 3. There are several first fillers 5; the sheath assembly is a double-layer co-extruded structure, including an inner sheath layer 10 and an outer sheath layer 11 arranged sequentially from the inside to the outside; the first conductor 1 includes a first conductor bundle 101 and a first conductor insulation layer 102 wrapped around the outside of the first conductor bundle 101; the first conductor bundle 101 is formed by stranding multiple bare copper wires with a diameter of 0.25mm, and the first conductor insulation layer 102 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 201 and a second conductor insulation layer 202 wrapped around the outside of the second conductor bundle 201; the second conductor bundle 201 is formed by stranding multiple bare copper wires with a diameter of 0.2mm, and the second conductor insulation layer 202... The insulation material is 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber; the third conductor 3 includes a third conductor bundle 301 and a third conductor insulation layer 302 wrapped around the outside of the third conductor bundle 301; the third conductor bundle 301 is formed by stranding multiple bare copper wires with a diameter of 0.15mm, and the third conductor insulation layer 302 is made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material; the fourth conductor 4 includes multiple fourth conductor bundles 401 and a fourth conductor insulation layer 402 wrapped around the outside of the fourth conductor bundle 401; a third wrapping layer 404 is provided at the outer end of the fourth conductor insulation layer 402, and multiple fourth fillers 403 are provided in the gap between the third wrapping layer 404 and the fourth conductor insulation layer 402; the... The outer side of the third wrapping layer 404 is also wrapped with a shielding layer 405, and the outer side of the shielding layer 405 is provided with a fourth wrapping layer 406; the wrapping overlap rate of the third wrapping layer 404 and the fourth wrapping layer 406 is 15% to 25%, and the third wrapping layer 404 and the fourth wrapping layer 406 are aluminum foil and nylon tape, respectively; the fourth filler 403 is untwisted polyester rope, and the shielding layer 405 is cross-woven tinned copper wire with a diameter of 0.10 mm; the fourth conductor insulation layer 402 is made of high-density polyethylene insulation material; the fourth conductor bundle 401 includes 930D ​​bulletproof wire 4011 and multiple first bare copper wires 4012 evenly arranged in a circle around the 930D ​​bulletproof wire 4011; the diameter of the first bare copper wires 4012 is 0.A second bare copper wire 4013 is provided between the outermost first bare copper wire 4012, and the second bare copper wire 4013 is formed by twisting two bare copper wires with a diameter of 0.15mm; the first wrapping layer 6 is nylon tape with a wrapping overlap rate of 15% to 25%; the second wrapping layer 9 is long-filament non-woven fabric with a wrapping overlap rate of 25% to 35%; the first filler 5 and the third filler 8 are both untwisted polyester ropes, and the second filler 7 is a solid strip; the solid strip is filled with a mesh tape and fiber filaments in the middle, and the solid strip is made of 90℃ low-smoke halogen-free flame-retardant irradiated cross-linked polyolefin insulation material; the inner sheath layer 10 and the outer sheath layer 11 are both made of TPU material.

[0024] In operation, the current is transmitted sequentially through a conductor assembly composed of multiple conductors of different diameters. The first conductor 1 is formed by stranding multiple bare copper wires with a diameter of 0.25mm and encased in a first conductor insulation layer 102, which is made of 125℃ irradiated cross-linked low-smoke halogen-free flame-retardant ethylene propylene rubber insulation material. The second conductor 2 is formed by stranding multiple bare copper wires with a diameter of 0.2mm and encased in a second conductor insulation layer 202 of the same material. The third conductor 3 is formed by stranding multiple bare copper wires with a diameter of 0.15mm and encased in a third conductor insulation layer 302 of the same material. The fourth conductor 4 is composed of multiple strands of fourth conductor bundle 401, including 930D ​​bulletproof wire 4011, a first bare copper wire 4012 with a diameter of 0.15mm, and a second bare copper wire 4013 formed by stranding two 0.15mm bare copper wires. The fourth conductor 4 is formed and wrapped with a high-density polyethylene insulation layer 402, which ensures stable current transmission. During transmission, the fourth conductor 4 is wrapped and shielded by a third wrapping layer 404 made of aluminum foil and a fourth wrapping layer 406 made of nylon tape. The shielding layer 405 uses tinned copper wire with a diameter of 0.10mm to cross-weave in order to reduce electromagnetic interference. At the same time, the first filler 5, the third filler 8 and the solid strip second filler 7 made of untwisted polyester rope and filled with mesh tape and fiber filaments are wrapped by the first wrapping layer 6 made of nylon tape and the second wrapping layer 9 made of long filament non-woven fabric to maintain the compactness and stability of the internal structure of the cable. Finally, the double-layer co-extruded sheath assembly composed of an inner sheath layer 10 and an outer sheath layer 11 made of TPU material provides abrasion resistance and corrosion resistance for the cable and improves the outer layer protection capability.

[0025] 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 GB DC charging interface cable with multi-wire diameter composite insulation, characterized in that: The device includes a conductor assembly and a sheath assembly. The sheath assembly wraps around the outside of the conductor assembly. A second wrapping layer (9) is provided between the conductor assembly and the sheath assembly. A second filler (7) and a third filler (8) are provided in the gap between the second wrapping layer (9) and the conductor assembly. There are several of the second filler (7) and the third filler (8). 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) and the third conductor (3) are symmetrically arranged. There are several fourth conductors (4). A first wrapping layer (6) is provided at the outer end of the second conductor (2) and the third conductor (3). There are several first fillers (5) in the gap between the first wrapping layer (6) and the second conductor (2) and the third conductor (3). The sheath assembly is a double-layer co-extruded structure, including an inner sheath layer (10) and an outer sheath layer (11) arranged sequentially from the inside to the outside.

2. The multi-wire diameter, composite insulated, 300 A, GB standard, DC charging interface cable of claim 1, wherein: The first conductor (1) includes a first conductor bundle (101) and a first conductor insulation layer (102) wrapped around the outside of the first conductor bundle (101); the first conductor bundle (101) is made of multiple bare copper wires with a diameter of 0.25 mm twisted together, and the first conductor insulation layer (102) is made of 125°C irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

3. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 1, characterized in that: The second conductor (2) includes a second conductor bundle (201) and a second conductor insulation layer (202) wrapped around the outside of the second conductor bundle (201); the second conductor bundle (201) is made of multiple bare copper wires with a diameter of 0.2 mm twisted together, and the second conductor insulation layer (202) 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 with multi-diameter composite insulation as described in claim 1, characterized in that: The third conductor (3) includes a third conductor bundle (301) and a third conductor insulation layer (302) wrapped around the outside of the third conductor bundle (301); the third conductor bundle (301) is made of multiple bare copper wires with a diameter of 0.15 mm twisted together, and the third conductor insulation layer (302) is made of 125℃ irradiated cross-linked low smoke halogen-free flame retardant ethylene propylene rubber insulation material.

5. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 1, characterized in that: The fourth conductor (4) includes multiple strands of fourth conductor bundles (401) and a fourth conductor insulation layer (402) wrapped around the outside of the fourth conductor bundles (401); a third wrapping layer (404) is provided at the outer end of the fourth conductor insulation layer (402), and multiple fourth fillers (403) are provided in the gap between the third wrapping layer (404) and the fourth conductor insulation layer (402); a shielding layer (405) is also wrapped around the outside of the third wrapping layer (404), and a fourth wrapping layer (406) is provided on the outside of the shielding layer (405).

6. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 5, characterized in that: The overlap rate of the third wrapping layer (404) and the fourth wrapping layer (406) is 15% to 25%. The third wrapping layer (404) and the fourth wrapping layer (406) are aluminum foil and nylon tape, respectively. The fourth filler (403) is untwisted polyester rope. The shielding layer (405) is tinned copper wire with a diameter of 0.10 mm that is cross-woven. The fourth conductor insulation layer (402) is made of high-density polyethylene insulation material.

7. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 5, characterized in that: The fourth conductor bundle (401) includes a 930D ​​bulletproof wire (4011) and a plurality of first bare copper wires (4012) evenly arranged in a circle around the 930D ​​bulletproof wire (4011); the diameter of the first bare copper wire (4012) is 0.15mm, and a second bare copper wire (4013) is also provided between the outermost first bare copper wires (4012), which is formed by twisting two bare copper wires with a diameter of 0.15mm.

8. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 1, characterized in that: The first wrapping layer (6) is a nylon tape with a wrapping overlap rate of 15% to 25%; the second wrapping layer (9) is a filament nonwoven fabric with a wrapping overlap rate of 25% to 35%.

9. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 1, characterized in that: The first filler (5) and the third filler (8) are both non-twisted polyester ropes, and the second filler (7) is a solid strip; the solid strip is filled with a mesh tape and fiber filaments in the middle, and the solid strip is made of 90℃ low smoke halogen-free flame retardant cross-linked polyolefin insulation material.

10. The 300A national standard DC charging interface cable with multi-diameter composite insulation according to claim 1, characterized in that: Both the inner sheath layer (10) and the outer sheath layer (11) are made of TPU material.

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