Liquid-cooled charging pile cable

Abstract

The utility model discloses a kind of liquid cooling charging pile cables. Liquid cooling charging pile cable includes cable core and sheath. Cable core includes tensile unit and multiple power units that are twisted with each other, the tensile unit is filled in the center of the cable core, multiple the power unit is twisted around the tensile unit, each the power unit includes liquid cooling pipe and multiple insulated wire core, multiple the insulated wire core is twisted around the liquid cooling pipe;Sheath is coated in the periphery of the cable core. The application improves the bending, torsion, dragging performance of each wire core by secondary twisting, reduces the risk of broken wire in terminal application. Through function division, the number of units involved in single twisting can be controlled. By setting the tensile unit in the center of the cable core, the frictional resistance between the power units can be increased, the probability of uneven tension on each wire core after wire core sliding can be reduced, and the reliability of the product can be improved.

Description

Technical Field

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

[0002] Liquid-cooled charging pile cables are cables that incorporate liquid-cooling pipes into traditional DC charging pile cables. This allows for the circulation of the cooling medium and its cooling effect to remove the heat generated by the cable, thereby achieving a higher current carrying capacity.

[0003] The most common structure for liquid-cooled charging pile cables is the copper-water separation structure, where the wire core and liquid cooling tube are separated. This structure has the advantage of allowing for individual assembly of the wire core and liquid cooling tube, reducing the difficulty of wire harness processing and sealing the liquid cooling tube. However, this structure involves a larger number of wire cores arranged in multiple layers, significantly impacting cable production and product lifespan. Cabling copper-water separation cables requires more cable reels, and tension control is more challenging due to the multi-layered arrangement of the wire cores. Since charging pile cables are subjected to dragging, bending, and torsion during end-user applications, these forces can easily cause smaller wires inside the cable core to break, rendering the cable unusable.

[0004] In summary, existing liquid-cooled charging pile cables suffer from technical problems such as complex production processes and insufficient product lifespan. Utility Model Content

[0005] The purpose of this application is to overcome the above-mentioned technical deficiencies and propose a liquid-cooled charging pile cable to solve the technical problems of complex production processes and insufficient product life in the prior art.

[0006] To achieve the above-mentioned technical objectives, the present application adopts the following technical solution:

[0007] This application provides a liquid-cooled charging pile cable, including a cable core and a sheath.

[0008] The cable core includes a tensile unit and multiple power units. The tensile unit is filled in the center of the cable core, and the multiple power units are stranded around the tensile unit. Each power unit includes a liquid cooling tube and multiple insulated wire cores, and the multiple insulated wire cores are stranded around the liquid cooling tube.

[0009] A sheath covers the outer periphery of the cable core.

[0010] In some embodiments of this application, the liquid cooling pipe is located at the center of the power unit, and the insulated wire cores are twisted and arranged around the periphery of the liquid cooling pipe.

[0011] In some embodiments of this application, the insulated core includes a conductor and an insulating layer, the insulating layer covering the periphery of the conductor.

[0012] In some embodiments of this application, the plurality of power units include two positive power lines and two negative power lines twisted together, and two power units with the same polarity are arranged side by side.

[0013] In some embodiments of this application, the cable core further includes a communication unit located in the gap between the power unit and the sheath and twisted together with the tensile unit and the power unit. The communication unit includes two communication lines twisted together and having opposite phases.

[0014] In some embodiments of this application, the cable core further includes an auxiliary power supply unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The auxiliary power supply unit includes two intertwined auxiliary power lines with opposite polarities.

[0015] In some embodiments of this application, the cable core further includes a control guide unit located in the gap between the power unit and the sheath and twisted together with the tensile unit and the power unit. The control guide unit includes a configuration channel line, a control guide line, and a charging connection confirmation line twisted together.

[0016] In some embodiments of this application, the cable core further includes a protective grounding unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The protective grounding unit includes a twisted protective grounding wire and a plurality of signal wires.

[0017] Compared with the prior art, the beneficial technical effects of the technical solution provided in this application include:

[0018] This application divides each wire core into multiple units according to its function. Each unit undergoes a single twisting process, followed by a secondary twisting between multiple units. This secondary twisting improves the bending, torsion, and drag resistance of each wire core, reducing the risk of breakage during end-use applications. Functional division allows control over the number of units involved in each twisting operation, keeping the total number of strands under 15, reducing reliance on the number of cable reels and lowering requirements for the cabling equipment. By incorporating tensile-resistant units at the center of the cable core, the frictional resistance between the power units is increased, reducing the probability of uneven tension on each core after slippage, improving product reliability, preventing uneven stress on the inner and outer layers under external forces, and extending the cable's lifespan. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this application, the accompanying drawings used in the embodiments will be briefly described below:

[0020] Figure 1 This is a schematic diagram of the structure of a liquid-cooled charging pile cable provided in an embodiment of this application.

[0021] Figure label:

[0022] Cable core 1, sheath 2;

[0023] Tensile unit 11, power unit 12, communication unit 13, auxiliary power supply unit 14, control and guidance unit 15, protective grounding unit 16;

[0024] Liquid cooling pipe 121, conductor 122, insulation layer 123, first wrapping tape layer 124, second wrapping tape layer 125. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0026] Those skilled in the art will understand that, in this specification, the term "comprising" is an open-ended expression, meaning that the stated feature is present but other features are excluded. Directional terms such as "upper," "lower," "left," and "right" refer to exemplary directions based on the accompanying drawings. Features specified as "first" or "second" implicitly include one or more of that feature. Singular expressions can also be used in plural forms. "Multiple" means two or more. The terms "installed," "connected," and "linked" can refer to a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection via an intermediate medium, and it can be a connection within two components. Furthermore, "linked" can include wireless connections.

[0027] The purpose of this application is to overcome the above-mentioned technical deficiencies and propose a liquid-cooled charging pile cable to solve the technical problems of complex production processes and insufficient product life in the prior art.

[0028] To achieve the above-mentioned technical objectives, the present application adopts the following technical solution:

[0029] like Figure 1 As shown. This application provides a liquid-cooled charging pile cable, including a cable core 1 and a sheath 2.

[0030] The cable core 1 includes a tensile unit 11 and a plurality of power units 12. The tensile unit 11 is filled in the center of the cable core 1, and the plurality of power units 12 are twisted around the tensile unit 11. Each power unit 12 includes a liquid cooling tube 121 and a plurality of insulated wire cores, and the plurality of insulated wire cores are twisted around the liquid cooling tube 121.

[0031] The sheath 2 covers the outer periphery of the cable core 1.

[0032] This application divides each wire core into multiple units according to its function. Each unit undergoes a single twisting process, followed by a secondary twisting between multiple units. This secondary twisting improves the bending, torsion, and drag resistance of each wire core, reducing the risk of wire breakage during end-use applications. Functional division allows control over the number of units involved in a single twisting operation, keeping the total number of strands below 15, reducing reliance on the number of cable reels and lowering requirements for the cabling equipment. By setting a tensile-resistant unit 11 at the center of the cable core 1, the frictional resistance between the power units 12 is increased, reducing the probability of uneven tension on each wire core after slippage, improving product reliability, preventing uneven stress on the inner and outer layers of the cable under external forces, and extending the cable's service life.

[0033] The tensile unit 11 comprises multiple fiber strands twisted together to form the tensile unit 11. For example, jute rope is made by twisting together multiple jute fibers. Jute fiber, as a natural fiber material, has good elasticity and toughness. Filling the gaps in the center of the cable core 1 with it effectively fills the space, preventing the cable core 1 from becoming loose or deformed. It provides mechanical support for the cable core 1, keeping it round and preventing twisting or deformation under external forces. Jute rope has a certain degree of hygroscopicity, which can absorb some moisture that may be generated inside the cable, thereby reducing the internal humidity of the cable. The elasticity and toughness of the jute rope allow the cable to better adapt to deformation when bent, reducing damage to the cable core 1 caused by bending.

[0034] In addition to jute rope, tensile unit 11 can also use a variety of materials, such as chemical fiber rope, metal wire, glass fiber, carbon fiber, or a combination of the above materials to balance strength, flexibility and cost.

[0035] Metal wires include steel wires or copper wires, while chemical fibers include nylon ropes, polyester ropes, Dyneema ropes, Kevlar ropes, or Vinylon ropes.

[0036] In some embodiments of this application, each of the insulated wire cores includes a conductor 122 and an insulating layer 123, the insulating layer 123 covering the periphery of the conductor 122.

[0037] The power line consists of multiple cores of the same specification. Each core includes a conductor 122 and a fluorinated ethylene propylene (FEP) insulation layer. These cores are first twisted with the liquid cooling pipe 121 according to the positive and negative conductors 122, forming multiple positive power lines and multiple negative power lines, with the liquid cooling pipe 121 located at the center.

[0038] The FEP insulation layer possesses excellent electrical insulation properties, high-temperature resistance, and chemical stability, effectively protecting conductor 122 and preventing current leakage and short circuits. The positive and negative conductors are first twisted with the liquid cooling pipe 121, with the liquid cooling pipe 121 located at the center of the twisted structure. This design allows for uniform distribution of coolant in the liquid cooling pipe 121, effectively dissipating heat from conductor 122. Multiple conductors 122 are twisted around the liquid cooling pipe 121; this arrangement facilitates rapid heat transfer from conductors 122 to the liquid cooling pipe 121, improving heat dissipation efficiency.

[0039] In some embodiments of this application, the power unit 12 further includes a first wrapping layer 124, which covers the periphery of a plurality of insulating layers 123.

[0040] The wrapping layer 124 maintains the structural stability of the power unit around the insulation layer 123. This layer may be made of graphene tape. Graphene has excellent electrical and thermal conductivity, which can effectively enhance the heat dissipation performance and electromagnetic shielding effect of the cable.

[0041] The high thermal conductivity of graphene tape enables rapid heat transfer from the inside of the cable to the outside, significantly improving heat dissipation efficiency and making it suitable for high-power charging applications. The conductivity of graphene helps form an effective electromagnetic shielding layer, reducing the cable's sensitivity to external electromagnetic interference and lowering the electromagnetic radiation generated by the cable itself. The graphene tape enhances the cable's mechanical strength, improving its tensile, impact, and abrasion resistance, thus extending its service life.

[0042] In some embodiments of this application, the liquid cooling pipe 121 is located at the center of the power unit 12, and the conductor 122 is arranged in a single layer between the liquid cooling pipe 121 and the first wrapping layer 124.

[0043] When current flows through conductor 122, heat is generated. Since conductor 122 is arranged in a single layer around liquid cooling pipe 121, the heat is rapidly conducted to the surface of liquid cooling pipe 121. A circulating cooling medium, such as water or ethylene glycol coolant, carries away the heat through the flow of the liquid, achieving efficient heat dissipation. The first wrapping layer 124 ensures structural stability between conductor 122 and liquid cooling pipe 121, preventing displacement and deformation of the power unit under operating conditions. Liquid cooling pipe 121, located at the center, provides a stable support structure for conductor 122, reducing deformation and stress concentration of the insulated core composed of conductor 122 and insulation layer 123 at high temperatures.

[0044] The liquid cooling tube 121 directly contacts the insulated core, rapidly dissipating heat and effectively reducing the temperature of conductor 122, thus improving the cable's current-carrying capacity. The single-layer arrangement of conductor 122 reduces the cable's radial dimensions, making it more compact and easier to install and route. The liquid cooling system stably maintains the temperature of conductor 122 within a safe range, reducing malfunctions caused by overheating and improving cable reliability.

[0045] In some embodiments of this application, a second wrapping layer 125 is also included, which covers the inner side of the sheath 2.

[0046] Each unit undergoes a first stranding process to form the basic cable structure. Multiple units are then stranded together to improve the cable's overall integrity and tensile strength. The cable core 1, after secondary stranding, is wrapped with a second wrapping layer 125, which can be made of non-woven fabric. Non-woven fabric offers excellent breathability and insulation, providing additional mechanical protection while also helping to reduce moisture and humidity inside the cable. Finally, the cable wrapped with non-woven fabric is extruded with a thermoplastic polyurethane (TPU) sheath 2. The TPU sheath 2 exhibits excellent abrasion resistance, weather resistance, and flexibility, protecting the cable from environmental damage.

[0047] The combination of secondary stranding and non-woven fabric wrapping improves the cable's tensile strength and overall integrity, enabling it to withstand greater mechanical stress and possess higher flexibility. The breathability of the non-woven fabric wrapping helps to expel moisture from inside the cable, while the TPU sheath prevents moisture from entering the cable, improving its waterproof and moisture-proof performance.

[0048] In some embodiments of this application, the plurality of power units 12 include two positive power lines and two negative power lines twisted together, and two power units 12 with the same polarity are arranged side by side.

[0049] Two positive power lines and two negative power lines are twisted together to form a power unit 12. Twisting reduces mutual interference between individual power lines, while improving the overall integrity and tensile strength of the cable. The twisting of the power lines and the parallel arrangement of power units 12 increase the cable's tensile strength, enabling it to withstand greater mechanical stress and possess higher flexibility. The overall twisted cable structure is more flexible and easier to bend, facilitating installation and wiring.

[0050] Among the multiple power units 12, those with the same polarity are arranged side by side. This arrangement helps to balance the current distribution within the cable, reducing electromagnetic interference and signal attenuation. The side-by-side arrangement of power units 12 with the same polarity helps to balance the current distribution within the cable, reducing electromagnetic interference and signal attenuation, and improving the cable's transmission performance.

[0051] In some embodiments of this application, the cable core further includes a communication unit 13, which is located in the gap between the power unit 12 and the sheath 2 and is twisted together with the tensile unit 11 and the power unit 12. The communication unit 13 includes two communication lines that are twisted together and have opposite phases.

[0052] The two communication lines are twisted together, effectively reducing electromagnetic interference and signal attenuation, and improving the tensile strength of the cable. The signals transmitted on the two lines are out of phase, and are subtracted at the receiving end by a differential amplifier to eliminate common-mode interference, retain the differential-mode signal, and improve signal quality. The communication unit 13 is located in the gap between the power unit 12 and the sheath 2, reducing the interference of the electromagnetic field generated by the power unit 12 on the communication signal.

[0053] In some embodiments of this application, the cable core further includes an auxiliary power supply unit 14, which is located in the gap between the power unit 12 and the sheath 2 and is twisted together with the tensile unit 11 and the power unit 12. The auxiliary power supply unit 14 includes two auxiliary power lines twisted together with opposite polarities.

[0054] The two auxiliary power lines are twisted together, a structure that helps reduce electromagnetic interference (EMI) and radio frequency interference (RFI) while increasing the cable's tensile strength. The twisted pairs counteract the effects of external electromagnetic fields on the line and also reduce electromagnetic radiation emitted by the line itself. The two auxiliary power lines have opposite polarities; when the voltage on one line is positive, the voltage on the other line is negative. The auxiliary power unit 14 is located in the gap between the power unit 12 and the sheath 2; this physical isolation helps reduce the impact of large currents in the power unit 12 on the auxiliary power lines. The primary function of the auxiliary power unit 14 is to provide additional power support for equipment. For example, in an electric vehicle charging system, the auxiliary power line can provide power to the charging pile's control system, communication module, or other auxiliary equipment. The auxiliary power unit 14 is twisted together with the power unit 12 and the communication unit 13 to form a complete cable structure. This design improves the overall mechanical strength and durability of the cable while facilitating installation and maintenance.

[0055] In some embodiments of this application, the cable core further includes a control guide unit 15, which is located in the gap between the power unit 12 and the sheath 2 and is twisted together with the tensile unit 11 and the power unit 12. The control guide unit 15 includes a configuration channel line, a control guide line and a charging connection confirmation line twisted together.

[0056] The configuration channel line transmits configuration information, such as device parameter settings, software updates, and startup commands. The control guide line transmits control signals used to control the device's operating status, such as start, stop, and power adjustment. The charging connection confirmation line transmits proximity sensor signals used to detect distance or position information between the device and an object.

[0057] The configuration channel wire, control guide wire, and charging connection confirmation wire are twisted together to form a control guide unit 15. The twisted structure helps to counteract the influence of external electromagnetic fields on the circuit, while also reducing the electromagnetic radiation emitted by the circuit itself. This is crucial for ensuring the clarity and accuracy of control signals. The twisted wire bundle is stronger and less prone to breakage than a single wire, and is also more flexible, facilitating wiring in complex environments. The twisted wire bundle is more robust and durable, improving the cable's tensile strength and flexibility, and extending the cable's service life.

[0058] In some embodiments of this application, the cable core further includes a protective grounding unit 16, which is located in the gap between the power unit 12 and the sheath 2 and is twisted together with the tensile unit 11 and the power unit 12. The protective grounding unit 16 includes a protective grounding wire twisted together and a plurality of signal wires.

[0059] Protective grounding wires are used to connect the metal casing of equipment to the ground as a safety measure to prevent the equipment from becoming energized due to insulation failure, thereby avoiding the risk of electric shock. Multiple signal lines transmit various signals, such as control signals and data signals.

[0060] The protective grounding wire and multiple signal wires are twisted together to form a protective grounding unit 16. The twisted structure helps to counteract the influence of external electromagnetic fields on the line, while also reducing the electromagnetic radiation emitted by the line itself. This reduces interference for the protective grounding wire, ensuring reliable grounding; for the signal wires, it reduces signal interference, ensuring signal clarity and accuracy. The twisted bundle is stronger and less prone to breakage than a single wire, and is also more flexible, facilitating wiring in complex environments.

[0061] The communication unit 13, auxiliary power supply unit 14, control guidance unit 15, protective grounding unit 16 and other auxiliary units are each provided with a wrapping tape layer on their outer side.

[0062] Compared with the prior art, the beneficial technical effects of the technical solution provided in this application include:

[0063] This application divides each wire core into multiple units according to its function. Each unit is first internally twisted, and then multiple units undergo secondary twisting. This secondary twisting improves the bending, torsion, and drag resistance of each wire core, reducing the risk of wire breakage during end-use applications. Functional division allows control over the number of units involved in each twisting operation, keeping the total number within 15 strands, reducing reliance on the number of cable reels and lowering requirements for the cable-making equipment. By setting a tensile-resistant unit 11 at the center of the cable core 1, the frictional resistance between the power units 12 is increased, reducing the probability of uneven tension on each wire core after slippage, improving product reliability, preventing uneven stress on the inner and outer layers of the cable under external forces, and extending the cable's service life.

[0064] Those skilled in the art will understand that the steps, measures, and schemes in the various operations, methods, processes, and procedures discussed in this application can be alternated, modified, rearranged, decomposed, combined, or deleted.

[0065] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Any other corresponding changes and modifications made based on the technical concept of this application should be included within the scope of protection of the claims of this application.

Claims

1. A liquid-cooled charging pile cable, characterized in that, include: The cable core includes a tensile unit and multiple power units. The tensile unit is filled in the center of the cable core, and the multiple power units are twisted around the tensile unit. Each power unit includes a liquid cooling tube and multiple insulated wire cores, and the multiple insulated wire cores are twisted around the liquid cooling tube. A sheath, covering the outer periphery of the cable core; The liquid cooling pipe is located at the center of the power unit, and the insulated wire cores are twisted and arranged around the periphery of the liquid cooling pipe; The insulated core includes a conductor and an insulating layer, with the insulating layer covering the periphery of the conductor.

2. The liquid-cooled charging pile cable according to claim 1, characterized in that, The plurality of power units include two positive power lines and two negative power lines twisted together, and two power units with the same polarity are arranged side by side.

3. The liquid-cooled charging pile cable according to claim 1, characterized in that, The cable core also includes a communication unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The communication unit includes two communication lines that are twisted together and have opposite phases.

4. The liquid-cooled charging pile cable according to claim 1, characterized in that, The cable core also includes an auxiliary power supply unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The auxiliary power supply unit includes two intertwined auxiliary power lines with opposite polarities.

5. The liquid-cooled charging pile cable according to claim 1, characterized in that, The cable core also includes a control guide unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The control guide unit includes a configuration channel line, a control guide line and a charging connection confirmation line twisted together.

6. The liquid-cooled charging pile cable according to claim 1, characterized in that, The cable core also includes a protective grounding unit, which is located in the gap between the power unit and the sheath and is twisted together with the tensile unit and the power unit. The protective grounding unit includes a twisted protective grounding wire and multiple signal wires.

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