A stretch-resistant electric vehicle charging cable
The electric vehicle charging cable, with its multi-layer structure design, solves the problem of insufficient tensile strength, achieves stable insulation and anti-interference performance over a wide temperature range, extends the cable's service life, and improves the safety of the charging process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHENGDU HUAERSEN ENVIRONMENTAL PROTECTION TECH
- Filing Date
- 2025-09-25
- Publication Date
- 2026-07-14
AI Technical Summary
Existing electric vehicle charging cables have insufficient tensile strength, which easily leads to loose structure, interlayer separation, insulation damage, decreased conductivity, and a narrow temperature resistance range of the insulation layer, affecting service life and safety.
The cable body is constructed with multiple strands of tinned copper wire, cross-linked polyethylene insulation, aramid fiber ring reinforcement, chlorinated polyethylene sheath, and copper tape shielding. Combined with a glass fiber rope filling layer, it forms a multi-layered synergistic protection, enhancing tensile strength, abrasion resistance, and temperature resistance.
It achieves stable insulation of the cable over a wide temperature range, prevents leakage, improves tensile strength, extends service life, enhances cable safety and reliability, and ensures the stability and anti-interference performance of power transmission.
Smart Images
Figure CN224501524U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle charging technology, specifically to a tensile-resistant electric vehicle charging cable. Background Technology
[0002] To meet the requirements of fast charging technology for electric vehicles, the charging cables used for electric vehicle charging have a high current-carrying capacity, generating a large amount of heat. To prevent overheating of the charging cables and improve safety during use, cooling pipes that can introduce cooling media are usually installed inside the cable core. That is, the cable core of electric vehicle charging cables is usually composed of power cores, signal cores, and cooling pipes, unlike conventional power cables.
[0003] However, existing electric vehicle charging cables generally suffer from insufficient tensile strength: some cables lack dedicated reinforcing structures or use only ordinary fibers as reinforcing layers, which easily lead to structural loosening and interlayer separation under long-term tensile stress, resulting in insulation damage, decreased conductivity, and even potential leakage hazards. Furthermore, the insulation layers of most cables have a narrow temperature resistance range, easily hardening and cracking at low temperatures and softening and deforming at high temperatures, affecting their service life. Therefore, those skilled in the art provide a tensile-resistant electric vehicle charging cable to solve the problems mentioned in the background. Utility Model Content
[0004] The purpose of this utility model is to provide a tensile-resistant electric vehicle charging cable to solve the problems mentioned in the background art of the prior art.
[0005] This utility model provides the following technical solution: a tensile-resistant electric vehicle charging cable, comprising a wire harness composed of multiple sets of cables, wherein multiple sets of cable assemblies are arranged inside the wire harness, each cable assembly includes a cable body, an insulation layer is fixedly connected to the outer surface of the cable body, an annular reinforcing layer is fixedly connected to the outer surface of the insulation layer, and a sheath is fixedly connected to the outer surface of the annular reinforcing layer.
[0006] As a preferred embodiment of the above technical solution, the annular reinforcing layer is woven from aramid fibers with a weaving density of not less than 90% and a thickness of 0.8-1.5 mm. The sheath is made of chlorinated polyethylene with a diamond-shaped anti-slip pattern on its outer surface, a pattern depth of 0.3-0.5 mm, and a thickness of 1.2-2.0 mm. The insulating layer is made of cross-linked polyethylene with a dielectric loss tangent of not more than 0.005 and a temperature resistance range of -40℃ to 125℃.
[0007] As a preferred embodiment of the above technical solution, the wire harness is wrapped with a shielding layer, which is made of copper tape with an overlap rate of not less than 15% and a thickness of 0.15-0.25mm. The wire harness is also filled with a glass fiber rope filling layer, which evenly separates multiple cable assemblies and has a filling density of 0.8-1.0g / cm³.
[0008] As a preferred embodiment of the above technical solution, the cable body is made of multiple strands of tin-plated copper wires twisted together, with the diameter of a single strand of copper wire being 0.1-0.2 mm, the twisting pitch being 10-15 mm, and the tin plating layer thickness being not less than 0.005 mm.
[0009] As a preferred embodiment of the above technical solution, an adhesive layer is provided between the annular reinforcing layer and the insulating layer. The adhesive layer is made of epoxy resin adhesive, the thickness of the adhesive layer is 0.1-0.2 mm, and the bonding strength is not less than 5 MPa, so that the annular reinforcing layer and the insulating layer are tightly bonded together.
[0010] As a preferred embodiment of the above technical solution, the inner wall of the sheath is provided with a number of reinforcing ribs extending along the length of the cable, the number of reinforcing ribs being 4-6, and the reinforcing ribs and the sheath being integrally formed, the cross-section of the reinforcing ribs being semi-circular with a radius of 0.3-0.4mm.
[0011] Compared with the prior art, the beneficial effects of this utility model are:
[0012] This utility model, through a multi-structure collaborative design, possesses several significant advantages: the core multi-strand tinned copper wire stranded cable body ensures efficient and stable conductivity while achieving corrosion resistance, low loss, and good flexibility thanks to the tin plating layer and reasonable stranding parameters; the cross-linked polyethylene insulation layer ensures reliable insulation over a wide temperature range, reducing the risk of leakage; the high-density braided aramid fiber ring reinforcement layer combined with a high-strength adhesive layer provides the cable with strong tensile strength, preventing structural deformation and damage; the chlorinated polyethylene sheath and the integrally molded inner wall reinforcing ribs improve the cable's tear resistance and abrasion resistance, while the anti-slip texture on the outer surface enhances ease of use; the outer copper tape shielding layer of the wire harness effectively isolates electromagnetic interference, ensuring stable charging signals and power transmission, while the internal glass fiber rope filling layer optimizes the structural stability of the wire harness and avoids compression wear between components. Overall, this cable can achieve safe and efficient power transmission in electric vehicle charging scenarios, and also possesses excellent tensile strength, anti-interference, aging resistance, temperature resistance, and ease of operation, effectively solving the problems of existing cables such as easy tensile damage, unstable insulation, and poor anti-interference, extending service life and improving the safety and reliability of the charging process. Attached Figure Description
[0013] Figure 1 A schematic diagram of the overall structure of a tensile-resistant electric vehicle charging cable;
[0014] Figure 2 A schematic diagram of a cable assembly connection for a tensile-resistant electric vehicle charging cable;
[0015] Figure 3 This is a schematic diagram of the insulation layer connection of a tensile-resistant electric vehicle charging cable;
[0016] Figure 4 This is a schematic diagram of the sheath connection of a tensile-resistant electric vehicle charging cable.
[0017] In the diagram: 1. Wire harness; 2. Cable assembly; 21. Cable body; 22. Insulation layer; 23. Annular reinforcing layer; 24. Sheath. Detailed Implementation
[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.
[0019] Please see Figures 1-4 As shown, this utility model provides a technical solution: a tensile-resistant electric vehicle charging cable, including a wire harness 1 composed of multiple sets of cables, with multiple sets of cable assemblies 2 arranged inside the wire harness 1. The cable assembly 2 includes a cable body 21, an insulation layer 22 fixedly connected to the outer surface of the cable body 21, an annular reinforcing layer 23 fixedly connected to the outer surface of the insulation layer 22, and a sheath 24 fixedly connected to the outer surface of the annular reinforcing layer 23.
[0020] The cable body 21, made of multiple strands of tinned copper wire, serves as the core of power transmission, ensuring stable conductivity during charging. The cross-linked polyethylene insulation layer 22 outside the cable body 21, with its excellent temperature resistance and low dielectric loss characteristics, isolates the cable body 21 from the outside, avoiding the risk of leakage. The annular reinforcing layer 23, made of high-density braided aramid fiber, is tightly bonded to the insulation layer 22 by an epoxy resin adhesive layer, providing core tensile support for the cable and preventing structural deformation during stretching. The chlorinated polyethylene sheath 24 outside the annular reinforcing layer 23 and the integrally formed reinforcing ribs on the inner wall further enhance tensile and tear resistance, while the diamond-shaped anti-slip texture on the outer surface improves grip stability during use. At the same time, the shielding layer wrapped with copper tape on the outside of the wire harness 1 can shield external electromagnetic interference, and the internal glass fiber rope filling layer evenly separates multiple cable assemblies 2, buffering the squeezing and collision between the assemblies. Ultimately, the entire cable achieves safe and efficient power transmission while possessing excellent tensile, abrasion-resistant, and anti-interference performance.
[0021] As one implementation method in this embodiment, please refer to Figures 1-4As shown, the annular reinforcing layer 23 is woven from aramid fiber with a weaving density of not less than 90%, and the thickness of the annular reinforcing layer 23 is 0.8-1.5mm. The sheath 24 is made of chlorinated polyethylene, and the outer surface of the sheath 24 is provided with diamond-shaped anti-slip texture with a texture depth of 0.3-0.5mm. The thickness of the sheath 24 is 1.2-2.0mm. The insulation layer 22 is made of cross-linked polyethylene, and the dielectric loss tangent of the insulation layer 22 is not greater than 0.005. The temperature resistance range of the insulation layer 22 is -40℃ to 125℃.
[0022] The annular reinforcing layer 23 is woven with aramid fibers with a braiding density of not less than 90% and a thickness of 0.8-1.5mm. The excellent tensile strength of aramid fibers provides core tensile support for the cable, effectively resisting the tensile forces that may be applied to the cable during charging and preventing damage to the cable structure due to tension. The sheath 24 is made of chlorinated polyethylene with a thickness of 1.2-2.0mm. Its material properties give the cable good wear resistance and aging resistance. Meanwhile, the diamond-shaped anti-slip texture on the outer surface with a depth of 0.3-0.5mm improves grip stability during use and prevents the cable from slipping during operation. The insulation layer 22 is made of cross-linked polyethylene with a dielectric loss tangent of not more than 0.005 and a temperature resistance range of -40℃ to 125℃. On the one hand, it isolates the cable body 21 from the outside, eliminating the risk of leakage and ensuring electrical safety. On the other hand, it can adapt to different temperature environments, ensuring stable insulation performance in both low-temperature and high-temperature scenarios. The three layers work together to ensure the cable's tensile strength, wear resistance, and insulation performance.
[0023] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the wire harness 1 is wrapped with a shielding layer, which is made of copper tape with an overlap rate of not less than 15% and a thickness of 0.15-0.25mm. The wire harness 1 is also filled with a fiberglass rope filling layer, which evenly separates multiple cable assemblies 2 and has a filling density of 0.8-1.0g / cm³.
[0024] The outer shielding layer of the wire harness 1 is made of copper tape with an overlap rate of not less than 15% and a thickness of 0.15-0.25mm. Utilizing the excellent electromagnetic shielding properties of copper tape, it can effectively block external electromagnetic signals from interfering with the internal power transmission of the cable, while preventing the electromagnetic radiation generated by the cable itself from affecting external equipment, thus ensuring the stability of signal and power transmission during charging. The fiberglass rope filling layer inside the wire harness 1, with a density of 0.8-1.0g / cm³, can evenly separate multiple cable assemblies 2, preventing the assemblies from being squeezed and rubbed against each other when the cable is bent, moved, or subjected to external forces, which could lead to structural damage. At the same time, the fiberglass rope itself has certain tensile and buffering properties, which can help improve the overall structural stability and tensile strength of the wire harness 1. The two work together to ensure the anti-interference performance of the cable while further optimizing the internal structural stability of the wire harness 1.
[0025] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the cable body 21 is made of multiple strands of tinned copper wires twisted together. The diameter of a single strand of copper wire is 0.1-0.2 mm, the twisting pitch is 10-15 mm, and the thickness of the tin plating layer is not less than 0.005 mm.
[0026] As the core component for power transmission, the cable body 21 adopts a multi-strand tinned copper wire stranded structure. The diameter of each copper wire is controlled between 0.1-0.2mm, which ensures the conductivity of the copper wire itself and enhances the overall flexibility of the cable body 21 through the multi-strand stranding design, avoiding the problem of easy breakage of single-strand thick copper wires. At the same time, the stranding pitch of 10-15mm ensures the tightness of the copper wire stranding and further enhances the tensile strength of the cable body 21, preventing the stranding structure from loosening during stretching. The tin plating layer with a thickness of not less than 0.005mm can effectively isolate the copper wire from contact with air and moisture, avoid oxidation and corrosion of the copper wire, extend the service life of the cable body 21, and reduce the contact resistance between copper wires, reducing losses during power transmission. Ultimately, the cable body 21 achieves stable and efficient power transmission while also possessing good flexibility, tensile strength, and corrosion resistance.
[0027] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, an adhesive layer is provided between the annular reinforcing layer 23 and the insulating layer 22. The adhesive layer is made of epoxy resin adhesive, the thickness of the adhesive layer is 0.1-0.2mm, and the bonding strength is not less than 5MPa, so that the annular reinforcing layer 23 and the insulating layer 22 are tightly bonded together.
[0028] Epoxy resin adhesive has excellent bonding properties, which can effectively eliminate the gap between the two layers and prevent relative displacement or separation between the annular reinforcing layer 23 and the insulation layer 22 when the cable is subjected to external forces such as tension, bending or vibration. At the same time, the adhesive layer can stably transfer the tensile strength of the annular reinforcing layer 23 to the insulation layer 22 and the internal cable body 21, ensuring that the tensile force is evenly distributed between the layers, preventing structural damage caused by local stress concentration, and thus ensuring the stable performance of the overall tensile strength of the cable. This lays the structural foundation for the insulation layer 22 to isolate leakage and the annular reinforcing layer 23 to provide tensile support.
[0029] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the inner wall of the sheath 24 is provided with several reinforcing ribs extending along the length of the cable. The number of reinforcing ribs is 4-6, and the reinforcing ribs and the sheath 24 are integrally formed. The cross-section of the reinforcing ribs is semi-circular with a radius of 0.3-0.4mm.
[0030] The inner wall of the sheath 24 features 4-6 reinforcing ribs extending along the cable length. These ribs are integrally molded with the sheath 24, preventing potential detachment or displacement during assembly and forming a stable overall load-bearing structure. The semi-circular cross-section with a radius of 0.3-0.4mm ensures the ribs' structural strength while minimizing their encroachment on the internal space of the sheath 24, preventing compression of the inner annular reinforcing layer 23. When the cable is subjected to tension, bending, or external impact, the reinforcing ribs, through their rigidity and toughness, distribute the external force, effectively inhibiting excessive deformation or tearing of the sheath 24. This further enhances the sheath 24's tensile and damage resistance. Combined with the chlorinated polyethylene material of the sheath 24, these ribs provide reliable protection for the cable's outer layer, ensuring the overall structural stability of the cable.
[0031] Working principle: The cable body 21, made of multiple strands of tin-plated copper wire, serves as the core for power transmission, ensuring both conductivity and flexibility, while the tin plating layer provides corrosion protection and reduces losses. The cross-linked polyethylene insulation layer 22 outside the cable body 21 isolates leakage current and is suitable for various temperature environments. Outside the insulation layer 22, a 0.1-0.2mm thick epoxy resin adhesive layer with a bonding strength ≥5MPa is bonded to a tightly adhered aramid fiber annular reinforcing layer 23 with a braiding density ≥90% and a thickness of 0.8-1.5mm. The cable is endowed with core tensile strength to prevent interlayer separation. The chlorinated polyethylene sheath 24 outside the annular reinforcing layer 23 and the 4-6 semi-circular integrally molded reinforcing ribs on the inner wall enhance tensile and tear resistance. The diamond-shaped anti-slip texture on the outer sheath 24 improves grip stability. A copper tape shielding layer with an overlap rate of ≥15% and a thickness of 0.15-0.25mm isolates electromagnetic interference, while an internal fiberglass rope filling layer of 0.8-1.0g / cm³ evenly separates the cable assembly 2 and buffers against compression and impact. The synergistic effect of these structures enables the cable to achieve safe and efficient power transmission while possessing excellent tensile strength, abrasion resistance, and anti-interference performance, making it suitable for electric vehicle charging scenarios.
[0032] The above embodiments are only used to illustrate the technical solution of this utility model, and are not intended to limit it.
Claims
1. A tensile-resistant electric vehicle charging cable, characterized in that: The cable harness (1) consists of multiple sets of cables. The cable harness (1) has multiple sets of cable assemblies (2) inside. The cable assembly (2) includes a cable body (21). An insulation layer (22) is fixedly connected to the outer surface of the cable body (21). An annular reinforcing layer (23) is fixedly connected to the outer surface of the insulation layer (22). A sheath (24) is fixedly connected to the outer surface of the annular reinforcing layer (23).
2. The tensile-resistant electric vehicle charging cable according to claim 1, characterized in that: The annular reinforcing layer (23) is woven from aramid fiber with a weaving density of not less than 90% and a thickness of 0.8-1.5 mm. The sheath (24) is made of chlorinated polyethylene and has a diamond-shaped anti-slip pattern on its outer surface with a pattern depth of 0.3-0.5 mm and a thickness of 1.2-2.0 mm. The insulating layer (22) is made of cross-linked polyethylene and has a dielectric loss tangent of not more than 0.005 and a temperature resistance range of -40℃ to 125℃.
3. The tensile-resistant electric vehicle charging cable according to claim 1, characterized in that: The wire harness (1) is wrapped with a shielding layer. The shielding layer is made of copper tape with an overlap rate of not less than 15% and a thickness of 0.15-0.25 mm. The wire harness (1) is also filled with a glass fiber rope filling layer. The filling layer evenly separates multiple cable assemblies (2) and has a filling density of 0.8-1.0 g / cm³.
4. The tensile-resistant electric vehicle charging cable according to claim 1, characterized in that: The cable body (21) is made of multiple strands of tin-plated copper wires twisted together. The diameter of a single strand of copper wire is 0.1-0.2 mm, the twisting pitch is 10-15 mm, and the thickness of the tin plating layer is not less than 0.005 mm.
5. The tensile-resistant electric vehicle charging cable according to claim 1, characterized in that: An adhesive layer is provided between the annular reinforcing layer (23) and the insulating layer (22). The adhesive layer is made of epoxy resin adhesive, the thickness of the adhesive layer is 0.1-0.2 mm, and the bonding strength is not less than 5 MPa, so that the annular reinforcing layer (23) and the insulating layer (22) are tightly bonded.
6. The tensile-resistant electric vehicle charging cable according to claim 1, characterized in that: The inner wall of the sheath (24) is provided with a number of reinforcing ribs extending along the length of the cable. The number of reinforcing ribs is 4-6, and the reinforcing ribs and the sheath (24) are integrally formed. The cross-section of the reinforcing ribs is semi-circular with a radius of 0.3-0.4mm.