A torsion-resistant long-life dc charging cable

Abstract

The utility model discloses a kind of high life DC charging cable of torsion resistance, including outer sheath and the cable core by signal line, power line, cable reinforcing core and auxiliary power line stranding being arranged in outer sheath, cable reinforcing core is located at the center position of outer sheath, signal line and several power lines are close to cable reinforcing core outside setting, auxiliary power line is close to outer sheath inside setting;Power line conductor in power line is stricken by tough copper conductor, conductor in signal line and auxiliary power line is uniformly distributed composite stranding by reinforcing core and tough copper conductor, and is covered by respective insulating layer again respectively.The cable core of the utility model is strung by power line, signal line, auxiliary power line, reinforcing core, outer sheath uses frosted wear-resistant sheath material;Through the simple structure, the wire core unit of cable core is stricken alone by tough copper conductor, or composite stranding with reinforcing core, so that signal line, auxiliary power line is not easy to break in the bending process of cable use, and life and safety are high.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable technology, specifically, to a torsion-resistant, long-life DC charging cable. Background Technology

[0002] With the rapid development and popularization of new energy vehicles, the frequency of charging at public charging stations is gradually increasing. During the charging process, customers repeatedly twist and bend the charging gun heads, causing damage to the signal wires in the charging cables (up to 0.5mm). 2 0.75mm 2 Easily broken wires, inability to provide signal feedback, and charging failures. Furthermore, there are no national standards requiring resistance to cable torsion; traditional charging cables have poor torsion resistance, cannot be used for long periods, require frequent replacements, and incur high maintenance costs. These defects severely limit cable lifespan and safety, necessitating the development of long-life cable solutions that are torsion resistant, durable, and adaptable to complex environments. Utility Model Content

[0003] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a torsion-resistant, long-life DC charging cable to improve the service life of the cable.

[0004] The present invention solves the above problems through the following technical solution:

[0005] A torsion-resistant, high-life DC charging cable includes: an outer sheath and a cable core disposed within the outer sheath, which is composed of signal lines, power lines, a cable reinforcing core, and an auxiliary power line twisted together. The cable reinforcing core is located at the center of the outer sheath, the signal lines and several power lines are disposed near the outer side of the cable reinforcing core, and the auxiliary power line is disposed near the inner side of the outer sheath.

[0006] The power conductors in the power lines are made of stranded tough copper conductors, while the conductors in the signal lines and auxiliary power lines are made of reinforced cores and tough copper conductors that are evenly distributed and stranded together, and then each is covered by its own insulation layer.

[0007] As a further improvement, the outer sheath is made of TPU material.

[0008] As a further improvement, the signal line, power line, auxiliary power line, and cable reinforcement core of the cable core are positioned by a splitter plate.

[0009] As a further improvement, after being positioned by the splitter board, the outer layer of the cable core has an entry angle between 40° and 55°.

[0010] As a further improvement, the tough copper conductor uses high elongation copper wire with an elongation of >30%.

[0011] As a further improvement, the cable has a four-core power line structure, including four power lines, one signal line, one cable reinforcement core, and at least one auxiliary power line and one ground line, with the four power lines arranged symmetrically in pairs.

[0012] As a further improvement, when the number of auxiliary power lines is even, the four power lines are also coaxially symmetrical.

[0013] As a further improvement, the power line conductor is made by first bundling the wires and then stranding them in the same direction.

[0014] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0015] This utility model discloses a torsion-resistant, high-life DC charging cable. The power conductor is made of stranded tough copper conductor, while the signal and auxiliary power lines are made of reinforced core and evenly distributed stranded tough copper conductor. The cable core is made of stranded power line, signal line, auxiliary power line, and reinforced core. The outer sheath is made of frosted wear-resistant sheath material. Through this simple structure, each core unit of the cable core is stranded individually with tough copper conductor or stranded in combination with reinforced core, so that the signal line and auxiliary power line are not easy to break during the bending process of the cable, resulting in high life and safety. Attached Figure Description

[0016] Figure 1 This is a cross-sectional schematic diagram of a torsion-resistant, long-life DC charging cable according to the present invention.

[0017] Figure 2 This is a cross-sectional schematic diagram of another type of torsion-resistant, high-life DC charging cable according to the present invention.

[0018] Figure 3 This is a cross-sectional structural diagram of the signal line and auxiliary power line of this utility model.

[0019] Figure label:

[0020] 1. Signal line; 2. Reinforcing core; 3. Power line; 4. Insulation layer; 5. Cable reinforcing core; 6. Auxiliary power line; 7. Outer sheath; 8. Tough copper conductor. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] Example:

[0023] Combined with appendix Figure 1-3 As shown, a torsion-resistant, high-life DC charging cable comprises five parts: conductor, insulation, reinforcing core, filler, and outer sheath. It includes an outer sheath 7, and signal lines 1, power lines 3, a cable reinforcing core 5, and an auxiliary power line 6 disposed within the outer sheath 7. The cable reinforcing core 5 is located at the center of the outer sheath 7. The signal lines 1 and several power lines 3 are positioned closest to the outer side of the cable reinforcing core 5. The auxiliary power line 6 is located between the power lines 3 or signal lines 1 (which are closest to the outer side of the cable reinforcing core) and the outer sheath 7, i.e., the auxiliary power line is positioned close to the inner side of the outer sheath.

[0024] The cable core is made of signal line 1, power line 3, auxiliary power line 6 and cable reinforcing core 5 twisted together and set inside the outer sheath 7. The outer sheath 7 is made of TPU material. TPU material is a frosted and wear-resistant sheath material with high wear resistance and good weather resistance, and can also meet the requirements of single-core combustion.

[0025] Preferably, the power conductor in the power line 3 is made of stranded tough copper conductor 8, and the conductors in the signal line 1 and the auxiliary power line 6 are made of reinforced core 2 and tough copper conductor 8 evenly distributed and stranded, and then covered by their respective insulation layers 4.

[0026] When there is only one reinforcing core 2, it is positioned between the signal line 1 and the auxiliary power line 6. In this embodiment, there are several reinforcing cores 2, which are evenly distributed in each layer of the tough copper conductor 8 and are compositely stranded to form the conductors within the signal line 1 and the auxiliary power line 6.

[0027] A further technical solution involves twisting together a signal line 1, a power line 3, an auxiliary power line 6, and a cable reinforcing core 5, and positioning it via a splitter plate to ensure an entry angle of 40%–55%. Filling and other methods are used to ensure uniform distribution of the filler and cable core, preventing misalignment or displacement.

[0028] Tough copper conductor 8 is a high elongation copper wire with an elongation of >30%;

[0029] In this embodiment, a four-core power line structure is used, including four power lines, one signal line, one cable reinforcement core, two auxiliary power lines, and one ground line. The four power lines are arranged symmetrically in pairs, and the two auxiliary power lines are also arranged symmetrically. Figure 1-2 As shown.

[0030] A further improved design uses a method of first bundling the wires and then stranding them in the same direction. The power and ground conductors use a stranded structure of pure copper monofilaments, i.e., tough copper conductors. The signal and auxiliary power conductors are made of a mixture of tough copper conductors and high-strength cable reinforcing cores, with the reinforcing cores evenly distributed between each layer of tough copper conductors. The distribution method is shown in [the diagram]. Figure 2.

[0031] To ensure consistent tension during cable torsion, the cable core is designed to improve the tensile strength of AC charging cables.

[0032] The uniform tension of each pure copper filament is beneficial to improving the tensile strength of the torsion-resistant, long-life DC charging cable. All core units, namely signal lines, power lines, auxiliary power lines, and cable reinforcing cores, must pass through the splitter plate. The cable reinforcing core is located at the very center of the cable core and has the greatest tension during the cable core torsion process. The angle of the outer cable core entering the cable core is between 40° and 55°. The cable forming mold adopts an integrated mold, and the angle of the entering wire should be smooth to ensure that the filler, core, and mold slide evenly during the cable forming and rotation process.

[0033] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A torsion-resistant, high-life DC charging cable, characterized in that, include: The outer sheath and the cable core, which is made up of signal lines, power lines, cable reinforcing core and auxiliary power lines, are set inside the outer sheath. The cable reinforcing core is located at the center of the outer sheath, the signal lines and several power lines are set near the outside of the cable reinforcing core, and the auxiliary power lines are set near the inside of the outer sheath. The power conductors in the power lines are made of stranded tough copper conductors, while the conductors in the signal lines and auxiliary power lines are made of reinforced cores and tough copper conductors that are evenly distributed and stranded together, and then each is covered by its own insulation layer.

2. The torsion-resistant, high-life DC charging cable according to claim 1, characterized in that, The outer sheath is made of TPU material.

3. The torsion-resistant, high-life DC charging cable according to claim 1, characterized in that, The signal lines, power lines, auxiliary power lines, and cable reinforcing cores of the cable core are positioned by a splitter board.

4. The torsion-resistant, high-life DC charging cable according to claim 3, characterized in that, After being positioned by the splitter board, the outer layer of the cable core has an entry angle between 40° and 55°.

5. The torsion-resistant, high-life DC charging cable according to claim 1, characterized in that, The tough copper conductor is made of high elongation copper wire with an elongation of >30%.

6. The torsion-resistant, high-life DC charging cable according to claim 1, characterized in that, The cable has a four-core power line structure, including four power lines, one signal line, one cable reinforcement core, and at least one auxiliary power line and one ground line, with the four power lines arranged symmetrically in pairs.

7. The torsion-resistant, high-life DC charging cable according to claim 6, characterized in that, When the number of auxiliary power lines is even, the four power lines are also coaxial and symmetrical.

8. A torsion-resistant, high-life DC charging cable according to any one of claims 1-7, characterized in that, The power line conductor is produced by first bundling the wires together and then stranding them in the same direction.

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