A new energy vehicle integrated cable

Abstract

This utility model discloses a comprehensive cable for new energy vehicles, including an outer sheath. The outer sheath contains several wire cores and several cooling pipes. Each wire core includes a central conductor, a first insulation layer, and a first shielding layer. The first insulation layer covers the outside of the central conductor, and the first shielding layer covers the outside of the first insulation layer. Each cooling pipe includes an inner heat-conducting layer and an outer heat-conducting layer covering the outside of the inner heat-conducting layer, with coolant channels formed in the inner heat-conducting layer. The outer sheath includes a second shielding layer and a sheath layer, with the sheath layer covering the outside of the second shielding layer. This structure, by staggering the wire cores and cooling pipes, effectively improves the cable's heat dissipation performance, preventing overheating in high-temperature environments and thus enhancing the cable's high-temperature resistance. Simultaneously, the staggered distribution also strengthens the overall structural strength of the cable, improving its tensile and bending resistance, and meeting flexibility requirements.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle cables, and in particular to a new energy vehicle integrated cable. Background Technology

[0002] The rapid development of the new energy vehicle industry has placed higher demands on the reliability of internal vehicle cables. New energy vehicle cables are core components for energy transmission and signal control in electric vehicles, and their technological development is directly related to the safety, reliability, and performance of the entire vehicle.

[0003] New energy vehicle cables typically consist of a conductor, an insulation layer, a shielding layer, and an outer jacket. During operation, these cables not only need to ensure stable power transmission but also, depending on the scenario and application, possess properties such as high temperature resistance, high voltage resistance, lightweight design, interference resistance, bending resistance, corrosion resistance, and flame retardancy.

[0004] The wiring environment inside new energy vehicles is complex, and at present, new energy vehicle cables cannot simultaneously accommodate multiple characteristics such as high temperature resistance, flexibility, and interference resistance. Utility Model Content

[0005] The technical problem solved by this utility model is to provide a comprehensive cable for new energy vehicles that combines high temperature resistance, flexibility, and anti-interference properties.

[0006] The technical solution adopted by this utility model to solve its technical problem is: a new energy vehicle integrated cable, including an outer sheath, wherein a number of wire cores and a number of cooling pipes are arranged inside the outer sheath;

[0007] The wire core includes a central conductor, a first insulation layer, and a first shielding layer, wherein the first insulation layer covers the outside of the central conductor, and the first shielding layer covers the outside of the first insulation layer;

[0008] The cooling pipe includes an inner heat-conducting layer and an outer heat-conducting layer covering the outside of the inner heat-conducting layer, and a coolant channel is formed in the inner heat-conducting layer;

[0009] The outer sheath includes a second shielding layer and a sheath layer, with the sheath layer covering the outside of the second shielding layer.

[0010] Furthermore, several wire cores and several cooling tubes are staggered and distributed inside the outer sheath, or

[0011] Each conductor is surrounded by several cooling tubes.

[0012] Furthermore, it also includes a fiber braided layer disposed between the inner heat-conducting layer and the outer heat-conducting layer.

[0013] Furthermore, a temperature detection sensor is provided on the inner side of the outer sheath.

[0014] Furthermore, the central conductor comprises several stranded single wires, wherein the single wires are high-purity copper wires.

[0015] Furthermore, the first insulating layer is made of polyvinyl chloride or cross-linked polyolefin, and the first shielding layer is a composite structure of aluminum foil and drainage wire.

[0016] Furthermore, the inner thermally conductive layer is a hydrolysis-resistant polymer or a TPV elastomer.

[0017] Furthermore, the outer thermally conductive layer is a high thermal conductivity polymer or a radiation coating.

[0018] Furthermore, the second shielding layer is a tin-plated copper wire braided structure with a braiding density of 85% to 95% and a braiding angle of 30° to 45°.

[0019] Furthermore, the sheath layer is made of flame-retardant and wear-resistant material, and the thickness of the sheath layer is 2-4 mm.

[0020] The beneficial effects of this utility model are:

[0021] 1. By arranging several wire cores and several cooling tubes in an alternating pattern, the heat dissipation performance of the cable can be effectively improved, preventing overheating in high-temperature environments and thus enhancing the cable's high-temperature resistance. Simultaneously, the staggered distribution can also strengthen the overall structural strength of the cable, improving its tensile and bending resistance, and meeting flexibility requirements.

[0022] 2. By designing multiple shielding layers, the anti-interference capability of the cable can be improved.

[0023] 3. By adding a fiber braided layer inside the cooling pipe, the pressure resistance and bending resistance of the cooling pipe are increased.

[0024] 4. This structure, through the setting of temperature detection sensors, can monitor the cooling efficiency of the cooling pipe in real time, promptly identify and resolve potential problems, and ensure that the cable is always in the best working condition. Attached Figure Description

[0025] Figure 1 This is a cross-sectional schematic diagram of the first embodiment of the integrated cable for new energy vehicles.

[0026] Figure 2 This is a cross-sectional schematic diagram of a second embodiment of the integrated cable for new energy vehicles.

[0027] Figure 3 This is a cross-sectional schematic diagram of the third embodiment of the integrated cable for new energy vehicles.

[0028] Figure 4This is a cross-sectional schematic diagram of the fourth embodiment of the integrated cable for new energy vehicles.

[0029] The components in the diagram are labeled as follows: core 1, center conductor 11, first insulation layer 12, first shielding layer 13, cooling pipe 2, coolant channel 21, inner heat-conducting layer 22, outer heat-conducting layer 23, fiber braided layer 24, outer sheath 3, second shielding layer 31, sheath layer 32, and temperature detection sensor 4. Detailed Implementation

[0030] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0031] like Figure 1 The illustrated integrated cable for new energy vehicles includes an outer sheath 3, inside which are arranged a plurality of wire cores 1 and a plurality of cooling pipes 2;

[0032] The core 1 includes a central conductor 11, a first insulation layer 12 and a first shielding layer 13. The first insulation layer 12 covers the outside of the central conductor 11, and the first shielding layer 13 covers the outside of the first insulation layer 12.

[0033] The cooling pipe 2 includes an inner heat-conducting layer 22 and an outer heat-conducting layer 23 covering the outside of the inner heat-conducting layer 22, and a coolant channel 21 is formed in the inner heat-conducting layer 22;

[0034] The outer sheath 3 includes a second shielding layer 31 and a sheath layer 32, with the sheath layer 32 covering the outside of the second shielding layer 31.

[0035] Specifically, in the above structure, the arrangement of several wire cores 1 and several cooling pipes 2 makes the overall cable structure more compact and the heat dissipation efficiency higher. The wire cores 1 are responsible for transmitting power or signals, while the cooling pipes 2 effectively dissipate the heat generated during cable operation through coolant circulation, ensuring stable operation of the cable in high-temperature environments. This design not only improves the cable's high-temperature resistance but also enhances its flexibility and anti-interference capabilities due to the presence of the cooling pipes 2.

[0036] In this embodiment, the distribution of the wire core 1 and the cooling pipe 2 is in two ways, specifically:

[0037] The first distribution method: such as Figure 1 As shown, several wire cores 1 and several cooling tubes 2 are staggered and distributed inside the outer sheath 3.

[0038] Specifically, this staggered distribution maximizes the use of the space inside the outer sheath 3, resulting in a more uniform spacing between the core 1 and the cooling pipe 2, thus avoiding problems such as localized overheating or uneven cooling. Simultaneously, the staggered distribution enhances the overall structural strength of the cable, improving its tensile and bending resistance to meet flexibility requirements. Furthermore, this distribution method facilitates heat dissipation, enabling the cable to maintain more stable performance in high-temperature environments.

[0039] The second distribution method: such as Figure 2 As shown, each wire core 1 is surrounded by several cooling tubes 2.

[0040] Specifically, this wraparound distribution ensures that each conductor 1 receives adequate cooling, improving the cable's heat dissipation efficiency and high-temperature resistance. Because the cooling pipes 2 tightly surround the outside of the conductor 1, they effectively and quickly dissipate the heat generated during operation, preventing performance degradation or damage caused by overheating. Simultaneously, this wraparound distribution enhances the cable's flexibility and anti-interference capabilities, enabling it to maintain more stable performance in complex wiring environments. Furthermore, the presence of the cooling pipes 2 also increases the cable's mechanical strength to some extent, improving its tensile and bending resistance and extending its service life.

[0041] In this embodiment, as Figure 3 As shown, it also includes a fiber braided layer 24 disposed between the inner heat-conducting layer 22 and the outer heat-conducting layer 23.

[0042] Specifically, the fiber braided layer 24 can further enhance the strength and toughness of the cooling pipe 2, prevent the cooling pipe 2 from being damaged or deformed during use, and ensure that the cooling pipe 2 effectively cools the cable.

[0043] In this embodiment, as Figure 4 As shown, a temperature detection sensor 4 is provided on the inner side of the outer sheath 3.

[0044] Specifically, the aforementioned temperature sensor 4 can be a flexible temperature sensor. This sensor can detect the temperature data of the cable's internal environment in real time and transmit the data to the vehicle's control system, thereby enabling real-time monitoring and adjustment of the cable temperature. If the cable temperature becomes too high, the control system can take timely measures, such as increasing coolant flow or reducing current load, to prevent overheating and potential safety hazards. This intelligent temperature monitoring design not only improves the cable's safety performance but also enhances the overall intelligence level of the vehicle.

[0045] In this embodiment, the central conductor 11 comprises several stranded single wires, which are high-purity copper wires.

[0046] Specifically, the use of high-purity copper wire ensures excellent conductivity and corrosion resistance of core 1, improving the cable's transmission efficiency and service life. Simultaneously, the stranded design enhances the flexibility and tensile strength of core 1, enabling the cable to maintain more stable performance in complex wiring environments.

[0047] In this embodiment, the first insulating layer 12 is polyvinyl chloride or cross-linked polyolefin, and the first shielding layer 13 is a composite structure of aluminum foil and drainage line.

[0048] Specifically, polyvinyl chloride and cross-linked polyolefin, used as insulation materials, possess excellent insulation and high-temperature resistance, effectively isolating the central conductor 11 from the external environment and ensuring stable cable operation. Simultaneously, the composite structure of aluminum foil and drain wires serves as a shielding layer, effectively shielding against external electromagnetic interference and enhancing the cable's anti-interference capability. This combination of insulation and shielding layers not only guarantees the cable's electrical performance but also improves its reliability and safety.

[0049] In this embodiment, the inner thermally conductive layer 22 is a hydrolysis-resistant polymer or TPV elastomer.

[0050] Specifically, the hydrolysis-resistant polymer can be long-chain nylon PA12, PA612, etc. Since the inner heat-conducting layer 22 directly contacts the ethylene glycol-based cooling medium, it needs to have good hydrolysis resistance and resistance to corrosion from the ethylene glycol-based cooling medium to ensure the long-term stable operation of the cooling pipe 2. TPV elastomer, on the other hand, has excellent elasticity, wear resistance, and aging resistance, which can further improve the durability and reliability of the cooling pipe 2. This choice of material for the inner heat-conducting layer 22 not only ensures effective heat dissipation of the cooling pipe 2 but also improves its mechanical properties and chemical stability.

[0051] In this embodiment, the outer thermal conductive layer 23 is a high thermal conductivity polymer or a radiation coating.

[0052] Specifically, the high thermal conductivity polymer can be TPU containing ceramic fillers, etc., and the radiation coating can be graphene, etc. The high thermal conductivity polymer and radiation coating, as materials for the outer thermal conductive layer 23, possess excellent thermal conductivity and thermal radiation efficiency, enabling rapid transfer of heat from the inner thermal conductive layer 22 to the external environment, further improving the cable's heat dissipation capacity. Simultaneously, the high thermal conductivity polymer and radiation coating also exhibit good weather resistance and corrosion resistance, protecting the cooling pipe 2 from external environmental corrosion and extending the cable's service life. This choice of material for the outer thermal conductive layer 23 not only optimizes the cable's heat dissipation performance but also enhances its durability and reliability.

[0053] In this embodiment, the second shielding layer 31 is a tin-plated copper wire braided structure, the braiding density of the tin-plated copper wire braided structure is 85% to 95%, and the braiding angle of the tin-plated copper wire braided structure is 30° to 45°.

[0054] Specifically, the tin-plated copper wire braided structure serves as the second shielding layer 31. Its high-density braiding design effectively shields against external electromagnetic interference, improving the cable's anti-interference performance. Simultaneously, the selection of the braiding angle enhances the cable's flexibility and bending resistance while maintaining shielding effectiveness, allowing the cable to maintain more stable performance in complex wiring environments. This design of the second shielding layer 31 not only improves the cable's electrical performance but also enhances its mechanical properties and reliability.

[0055] In this embodiment, the sheath layer 32 is a flame-retardant and wear-resistant material, and the thickness of the sheath layer 32 is 2-4 mm.

[0056] Specifically, the aforementioned flame-retardant and wear-resistant materials can be thermoplastic polyurethane (TPU), aramid fiber composite materials, etc., and the thickness of the sheath layer 327 can be 2-4mm, such as 2mm, 3mm, 4mm, etc. This thickness selection can ensure that the cable has sufficient mechanical strength and wear resistance, while avoiding excessive weight of the cable due to an excessively thick sheath layer 327, which is in line with the development trend of lightweighting of new energy vehicles.

[0057] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A composite cable for new energy vehicles, characterized in that: It includes an outer sheath (3), and the outer sheath (3) is provided with a plurality of wire cores (1) and a plurality of cooling pipes (2); The core (1) includes a center conductor (11), a first insulation layer (12) and a first shielding layer (13), wherein the first insulation layer (12) covers the outside of the center conductor (11) and the first shielding layer (13) covers the outside of the first insulation layer (12); The cooling pipe (2) includes an inner heat-conducting layer (22) and an outer heat-conducting layer (23) covering the outside of the inner heat-conducting layer (22), wherein a coolant channel (21) is formed in the inner heat-conducting layer (22); The outer sheath (3) includes a second shielding layer (31) and a sheath layer (32), the sheath layer (32) covering the outside of the second shielding layer (31).

2. The integrated cable for new energy vehicles as described in claim 1, characterized in that: Several wire cores (1) and several cooling tubes (2) are staggered and distributed inside the outer sheath (3), or Each conductor (1) is surrounded by several cooling tubes (2).

3. The integrated cable for new energy vehicles as described in claim 1, characterized in that: It also includes a fiber braided layer (24) disposed between the inner heat-conducting layer (22) and the outer heat-conducting layer (23).

4. The integrated cable for new energy vehicles as described in claim 1, characterized in that: A temperature detection sensor (4) is provided on the inner side of the outer sheath (3).

5. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The central conductor (11) comprises several stranded single wires, which are high-purity copper wires.

6. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The first insulating layer (12) is polyvinyl chloride or cross-linked polyolefin, and the first shielding layer (13) is a composite structure of aluminum foil and drainage line.

7. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The inner thermally conductive layer (22) is a hydrolysis-resistant polymer or TPV elastomer.

8. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The outer thermal conductive layer (23) is a high thermal conductivity polymer or a radiation coating.

9. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The second shielding layer (31) is a tin-plated copper wire braided structure with a braiding density of 85% to 95% and a braiding angle of 30° to 45°.

10. The integrated cable for new energy vehicles as described in claim 1, characterized in that: The sheath layer (32) is made of flame-retardant and wear-resistant material, and the thickness of the sheath layer (32) is 2-4 mm.

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