High-thermal-conductivity liquid-cooled high-power charging cable

Abstract

The utility model discloses a high heat conduction liquid cooling high -power charging cable, including the ground wire core that sets gradually from inside to outside, control wire core layer, main wire core layer, around the package layer and outer sheath, the main wire core layer includes at least a pair of liquid cooling pipe, a plurality of power line core and be located in the interstice of liquid cooling pipe and power line core's filling layer, and each power line core is contacted with at least one liquid cooling pipe, the filling layer adopts the heat rate not less than 1.0W / m. K and the viscosity 10s of 1 is 80~300Pa. S between s of heat conduction sealant solidification and form. The utility model discloses the power line core of main heating and liquid cooling pipe direct contact, and the control wire core of the smaller heating amount is separated from the main wire core layer, and the control wire core layer is formed separately, and the influence of the heating amount of power line core to control wire core layer is relieved, and the filling layer adopts the solidification of high -performance heat conduction joint material, can improve the heat conductivity, and has certain flexibility simultaneously, reduces the heating amount of cable outer layer, improves the charging safety of new energy automobile.

Description

Technical Field

[0001] This utility model relates to the field of charging cable technology for electric vehicles, and in particular to a high thermal conductivity liquid-cooled high-power charging cable. Background Technology

[0002] In recent years, the scale of electric vehicles has expanded rapidly, gradually entering the public eye and greatly facilitating people's travel. However, the charging speed of electric vehicles is slow, seriously affecting the user experience. Furthermore, the utilization efficiency of charging stations is also low; traditional charging stations' DC charging cables carry a current of no more than 250A, with charging times exceeding 2 hours. Therefore, technicians decided to increase the current carrying capacity by increasing the conductor cross-section. However, this method produces charging cables that are heavy and have a large diameter, making them very inconvenient to use, and the conductor cost is high, significantly increasing the charging cost of electric vehicles.

[0003] To address this issue, engineers have employed liquid cooling to significantly reduce conductor temperature, thereby increasing current carrying capacity. For example, Chinese invention application CN115997258A discloses a charging cable that reduces cable diameter and weight, lowers charging costs, and improves user experience. However, while existing liquid-cooled high-power charging cables significantly increase current carrying capacity and reduce cable diameter and weight, their conventional filler materials, such as PP and cotton thread, have a thermal conductivity of only 0.2–0.5 W / (mk). This insufficient thermal conductivity prevents timely heat transfer from the conductor to the coolant, resulting in high cable sheath temperatures and compromising charging safety for new energy vehicles. Therefore, optimization of existing charging cables is necessary to mitigate these problems. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a high thermal conductivity liquid-cooled high-power charging cable that can quickly and effectively transfer the heat generated by the conductor to the liquid cooling pipe, reduce the heat generation of the outer layer of the cable, and improve the charging safety of new energy vehicles.

[0005] The technical solution to achieve the purpose of this utility model is:

[0006] A high thermal conductivity liquid-cooled high-power charging cable includes, from the inside out, a grounding core, a control core layer, a main core layer, a wrapping layer, and an outer sheath. The main core layer includes at least one pair of liquid-cooling tubes, multiple power cores, and a filling layer disposed in the gap between the liquid-cooling tubes and the power cores. Each power core is in contact with at least one liquid-cooling tube. The filling layer is made of a thermally conductive sealant with a heat rate of not less than 1.0 W / mK and a viscosity of 80 to 300 Pa·s.

[0007] Furthermore, the thermally conductive sealant is any one of a high thermal conductivity epoxy resin-based thermally conductive sealant, a highly filled silicone thermally conductive sealant, or a polyurethane-based thermally conductive sealant.

[0008] Furthermore, the control core layer includes a plurality of control cores evenly distributed circumferentially, and each control core includes a control core conductor and control core insulation extruded outside the control core conductor.

[0009] Furthermore, the power core includes a power core conductor and power core insulation extruded outside the power core conductor.

[0010] Furthermore, it also includes a communication cable core and a pair of auxiliary cores, with the two auxiliary cores arranged adjacent to each other. The power cores are provided in four groups, and are symmetrically arranged in pairs on both sides of the liquid cooling pipe. The communication cable core and the auxiliary cores are respectively arranged between two adjacent power cores.

[0011] Furthermore, the communication cable core includes a pair of communication cores and a protective layer extruded over the communication cores. The communication core includes a communication core conductor and a communication core insulation layer extruded over the communication core conductor.

[0012] Furthermore, the auxiliary core includes an auxiliary core conductor and auxiliary core insulation extruded outside the auxiliary core conductor.

[0013] Furthermore, the power cores are arranged in a circular pattern, the liquid cooling tube is in contact with the wrapping layer, and the communication cable core and auxiliary core are respectively located in the fan-shaped gap formed by two adjacent power cores and the wrapping layer.

[0014] Furthermore, the wrapping layer is an aluminum-plastic composite strip wrapping layer with the aluminum side facing outwards.

[0015] Furthermore, the outer sheath is a polyurethane sheath.

[0016] By adopting the above technical solution, this utility model has the following beneficial effects:

[0017] (1) In this invention, the main heat-generating power core is in direct contact with the liquid cooling pipe, and a main core layer is formed by a filling layer. Compared with the prior art, the control core with less heat generation is separated from the main core layer and formed separately to form a control core layer, which alleviates the influence of the heat generation of the power core on the control core layer. At the same time, the filling layer is made of high-performance thermally conductive sealant material, which can improve thermal conductivity and has a certain degree of flexibility, reduce the heat generation of the outer layer of the cable, and improve the charging safety of new energy vehicles.

[0018] (2) This utility model improves the reliability, maintainability and future expandability of the entire cable by pre-setting auxiliary cores as spare cores.

[0019] (3) By rationally arranging the positions of the liquid cooling pipe, power core, auxiliary core and communication cable core, this utility model makes the overall structure more compact and minimizes the outer diameter of the cable.

[0020] (4) This utility model uses an aluminum-plastic composite tape with the aluminum side facing out to wrap the cable core, avoiding the aluminum side facing the heat source of the cable core, causing heat radiation, which prevents the heat from dissipating quickly, thereby effectively improving the heat dissipation capacity and thus improving the current carrying capacity.

[0021] (5) This utility model adopts a polyurethane outer sheath, which reduces the weight of the cable, makes it more wear-resistant, and has better flexibility. Attached Figure Description

[0022] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein:

[0023] Figure 1 This is a schematic diagram of the structure of this utility model.

[0024] The labels in the attached diagram are:

[0025] Grounding core 1, Grounding core conductor 1-1, Grounding core insulation 1-2, Wrapping layer 2, Outer sheath 3, Liquid cooling pipe 4, Power core 5, Power core conductor 5-1, Power core insulation 5-2, Filling layer 6, Control core 7, Control core conductor 7-1, Control core insulation 7-2, Communication cable core 8, Protective layer 8-1, Communication core conductor 8-2, Communication core insulation layer 8-3, Auxiliary core 9, Auxiliary core conductor 9-1, Auxiliary core insulation 9-2. Detailed Implementation

[0026] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0027] (Example 1)

[0028] like Figure 1The high thermal conductivity liquid-cooled high-power charging cable shown includes, from the inside out, a grounding core 1, a control core layer, a main core layer, a wrapping layer 2, and an outer sheath 3. The main core layer includes at least one pair of liquid cooling tubes 4, multiple power cores 5, and a filling layer 6 disposed in the gap between the liquid cooling tubes 4 and the power cores 5. Each power core 5 is in contact with at least one liquid cooling tube 4, and the filling layer 6 is made of thermally conductive sealant with a heat rate of not less than 1.0 W / mK and a viscosity of 80 to 300 Pa·s in 10s⁻¹. By directly contacting the power core 5, which generates the most heat, with the liquid cooling pipe 4, and forming a main core layer through the filler layer 6, compared with the existing technology, the control core, which generates less heat, is separated from the main core layer and forms a separate control core layer, thus mitigating the impact of the heat generated by the power core 5 on the control core layer. At the same time, the filler layer 6 is made of high-performance thermally conductive sealant material, which can improve thermal conductivity and has a certain degree of flexibility, reducing the heat generation of the outer layer of the cable and improving the charging safety of new energy vehicles.

[0029] Specifically, the grounding core 1 includes a grounding core conductor 1-1 and grounding core insulation 1-2 extruded outside the grounding core conductor 1-1. The cross-section of the grounding core conductor 1-1 is 6mm². 2 The thickness of the grounding core insulation 1-2 is 0.7mm. The control core layer includes ten control cores 7 evenly distributed circumferentially. Each control core 7 includes a control core conductor 7-1 and control core insulation 7-2 extruded outside the control core conductor 7-1. The cross-section of the control core conductor 7-1 is 0.5mm². 2 The thickness of the insulation 7-2 of the control core is 0.5mm. There are four groups of power cores 5, symmetrically arranged in pairs on both sides of the liquid cooling pipe 4. Each power core 5 includes a power core conductor 5-1 and power core insulation 5-2 extruded outside the power core conductor 5-1. The cross-section of the power core conductor 5-1 is 16mm². 2 The insulation thickness of the power conductor core 5-2 is 0.7mm. The outer sheath 3 is a polyurethane sheath with a thickness of 1.7mm, which reduces the weight of the cable, makes it more wear-resistant, and provides better flexibility.

[0030] The main core layer also includes a communication cable core 8 and a pair of auxiliary cores 9. The auxiliary cores 9 are pre-installed as spare cores, improving the overall cable's reliability, maintainability, and future expandability. The two auxiliary cores 9 are arranged adjacent to each other, with the communication cable core 8 and auxiliary cores 9 positioned between two adjacent power cores 5. The communication cable core 8 includes a pair of communication cores and a protective layer 8-1 extruded over the communication cores. The communication core includes a communication core conductor 8-2 and a communication core insulation layer 8-3 extruded over the communication core conductor 8-2. The cross-section of the communication core conductor 8-2 is 0.5 mm². 2The insulation layer 8-3 of the communication wire core has a thickness of 0.5mm. The auxiliary wire core 9 includes the auxiliary wire core conductor 9-1 and the auxiliary wire core insulation 9-2 extruded outside the auxiliary wire core conductor 9-1. The cross-section of the auxiliary wire core conductor 9-1 is 1.5mm². 2 The thickness of the auxiliary core insulation 9-2 is 0.7mm. The power cores 5 are arranged in a circular pattern. The liquid cooling pipe 4 has an inner diameter of 4mm and an outer diameter of 6mm, and is filled with coolant. Its outer wall is in contact with the wrapping layer 2. The communication cable core 8 and the auxiliary core 9 are respectively located in the fan-shaped gap formed by two adjacent power cores 5 and the wrapping layer 2. The overall structure is more compact, minimizing the outer diameter of the cable.

[0031] The thermally conductive sealant is any one of the following: high thermal conductivity epoxy resin-based thermally conductive sealant, high-filler silicone thermally conductive sealant, or polyurethane-based thermally conductive sealant. For example, Dow Corning SCA series high thermal conductivity epoxy sealant, Shin-Etsu SCR series high thermal conductivity silicone sealant, and Sika PowerFlex series sealant. The wrapping layer 2 is an aluminum-plastic composite tape wrapping layer with the aluminum side facing outwards. This avoids the aluminum side directly facing the heat source of the cable core, which would cause heat radiation and prevent the heat from dissipating quickly. This effectively improves the heat dissipation capacity and, consequently, the current carrying capacity, reaching 400A. Compared to using cotton rope as a filler layer under the same conditions, this can increase the current carrying capacity by at least 100A.

[0032] This invention brings the main heat-generating power core into direct contact with the liquid cooling pipe, and forms a main core layer through a filler layer. Compared with the prior art, this design separates the control core, which generates less heat, from the main core layer to form a separate control core layer, thus mitigating the impact of the heat generated by the power core on the control core layer. At the same time, the filler layer is made of high-performance thermally conductive sealant, which improves thermal conductivity and has a certain degree of flexibility, reducing the heat generation of the outer layer of the cable and improving the charging safety of new energy vehicles.

[0033] 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 high thermal conductivity liquid-cooled high-power charging cable, characterized in that: The system comprises, from the inside out, a grounding core, a control core layer, a main core layer, a wrapping layer, and an outer sheath. The main core layer includes at least one pair of liquid-cooled tubes, multiple power cores, and a filler layer disposed in the gap between the liquid-cooled tubes and the power cores. Each power core is in contact with at least one liquid-cooled tube. The filler layer uses a material with a heat rate of not less than 1.0 W / mK and a viscosity of 10 s. -1 It is a thermally conductive sealant that has been cured to a pressure between 80 and 300 Pa·s.

2. The high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: The thermally conductive sealant is any one of high thermal conductivity epoxy resin-based thermally conductive sealant, high-filler silicone thermally conductive sealant, or polyurethane-based thermally conductive sealant.

3. The high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: The control core layer includes multiple control cores evenly distributed circumferentially. Each control core includes a control core conductor and control core insulation extruded outside the control core conductor.

4. The high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: The power core includes a power core conductor and power core insulation extruded outside the power core conductor.

5. The high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: It also includes a communication cable core and a pair of auxiliary cores, with the two auxiliary cores arranged adjacent to each other. The power cores are provided in four groups, and are symmetrically arranged in pairs on both sides of the liquid cooling pipe. The communication cable core and the auxiliary cores are respectively arranged between two adjacent power cores.

6. The high thermal conductivity liquid-cooled high-power charging cable according to claim 5, characterized in that: The communication cable core includes a pair of communication cores and a protective layer extruded over the communication cores. The communication core includes a communication core conductor and a communication core insulation layer extruded over the communication core conductor.

7. A high thermal conductivity liquid-cooled high-power charging cable according to claim 5, characterized in that: The auxiliary core includes an auxiliary core conductor and auxiliary core insulation extruded outside the auxiliary core conductor.

8. A high thermal conductivity liquid-cooled high-power charging cable according to claim 5, characterized in that: The power cores are arranged in a circular pattern, the liquid cooling tube is in contact with the wrapping layer, and the communication cable core and auxiliary core are respectively located in the fan-shaped gap formed by two adjacent power cores and the wrapping layer.

9. A high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: The wrapping layer is an aluminum-plastic composite tape wrapping layer with the aluminum side facing outwards.

10. A high thermal conductivity liquid-cooled high-power charging cable according to claim 1, characterized in that: The outer sheath is a polyurethane sheath.

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