A direct current charging cable

Abstract

The utility model belongs to cable manufacturing technical field discloses a direct current charging cable, including intermediate line body, elastic filling body, around the layer and outer sheath, intermediate line body includes two positive cable core, two negative cable core and an auxiliary cable core of same size and mutually twisted, intermediate line body has center gap, and elastic filling body fills in the center gap, and elastic filling body is with positive cable core, negative cable core and auxiliary cable core with arc curved surface and positive cable core, negative cable core and auxiliary cable core are pasted, and around the layer is with shape and is covered in the outer periphery of intermediate line body, and outer sheath is with shape and is covered in the outer periphery of around the layer. Such design can solve the existing direct current charging cable after using a period of time, the signal line of small line diameter, the positive line and the negative line of large line diameter, the internal copper wire is easy to break, the direct current charging cable is used, is often twisted, along with long -term use, the conductor in the internal cable core can produce deformation, influences its use safety problem.

Description

Technical Field

[0001] This utility model relates to the field of cable manufacturing technology, and in particular to a DC charging cable. Background Technology

[0002] With the development of the new energy sector, new energy vehicles are gradually becoming one of the ways people travel. New energy vehicles are generally charged using a combination of charging piles, charging cables, and charging guns through standardized interfaces. Charging methods for new energy vehicles include DC charging and AC charging. Home charging piles primarily use AC power, with charging times generally ranging from 4 to 6 hours. Public charging stations primarily use DC power, with charging times generally ranging from 30 to 60 minutes, enabling faster charging. Therefore, DC charging cables are generally heavier and have a larger wire diameter than AC charging cables. Due to the unreasonable angle design of the charging interfaces in some existing new energy vehicles, the charging gun is inserted into the charging interface at a downward angle, resulting in excessive bending at the connection between the charging cable and the charging gun. This area experiences significant stress, and after a period of use, the smaller signal wire cores in the DC charging cables used in public charging stations are prone to breakage, while the larger positive and negative wires are also prone to breakage, affecting the usability of the DC charging cables. Meanwhile, when new energy vehicle owners use DC charging cables to charge their vehicles, the DC charging cables are often twisted. With prolonged use, the conductors in the cable core will undergo significant deformation, affecting the safety of the DC charging cable during use.

[0003] Therefore, there is an urgent need for a DC charging cable to solve the above-mentioned technical problems. Utility Model Content

[0004] The purpose of this utility model is to provide a DC charging cable that can solve the problems of existing DC charging cables where, after a period of use, the copper wires inside the small-diameter signal wires and the large-diameter positive and negative wires are prone to breakage. At the same time, DC charging cables are often twisted during use, and with long-term use, the conductors in the cable core of the DC charging cable will deform, affecting its safety.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] A DC charging cable, comprising:

[0007] The intermediate cable body includes two positive cable cores of the same size and twisted together, two negative cable cores and one auxiliary cable core, the auxiliary cable core including a signal core group, a ground core and a power core twisted together; the intermediate cable body has a center gap.

[0008] An elastic filler is placed in the central gap, and the elastic filler is in contact with the positive cable core, the negative cable core and the auxiliary cable core with an arc-shaped curved surface;

[0009] A wrapping layer, which conformally wraps around the outer periphery of the intermediate line body;

[0010] An outer protective layer, which conforms to the outer periphery of the wrapping layer.

[0011] As a preferred technical solution for DC charging cables, the outer periphery of the positive core, the outer periphery of the negative core, the outer periphery of the auxiliary core, and the outer periphery of the elastic filler are all coated with lubricant.

[0012] As a preferred technical solution for DC charging cables, an aramid rope is disposed at the center of the elastic filler.

[0013] As a preferred technical solution for DC charging cables, the positive electrode core includes a positive conductor and a first insulation layer, and the negative electrode core includes a negative conductor and a second insulation layer. Both the positive conductor and the negative conductor are of type 6 conductor.

[0014] As a preferred technical solution for DC charging cables, the first insulation layer is red and the second insulation layer is black.

[0015] As a preferred technical solution for DC charging cables, the signal core assembly includes shielded signal lines and unshielded signal lines. The shielded signal lines are formed by twisting together multiple shielded signal cores, and the unshielded signal lines are formed by twisting together multiple unshielded signal cores. The outer periphery of each shielded signal core is covered with a metal braided layer.

[0016] As a preferred technical solution for DC charging cables, the twisting pitch ratio of the multiple shielded signal cores and the multiple unshielded signal cores is 9 to 12.

[0017] As a preferred technical solution for DC charging cables, the outer sheath is made of polyurethane.

[0018] As a preferred technical solution for DC charging cables, the elastic filler and the intermediate wire are twisted together, and the twisting diameter ratio of the intermediate wire and the elastic filler is less than or equal to 16.

[0019] As a preferred technical solution for DC charging cables, the elastic filler is made of thermoplastic elastomer, polyolefin elastomer, or synthetic rubber.

[0020] The advantages of the DC charging cable provided by this utility model compared to the prior art are as follows:

[0021] 1. By twisting two positive cable cores, two negative cable cores, and one auxiliary cable core to form an intermediate cable body, the existing single positive cable is split into two positive cable cores, and the existing single negative cable is split into two negative cable cores. At the bend of the DC charging cable, compared with the existing single positive and single negative cable structure, the positive and negative cable cores are subjected to more uniform stress, which greatly reduces the stress on the positive and negative cable cores when the DC charging cable is in a bending state, and reduces the risk of copper wire breakage inside the positive and negative cable cores.

[0022] 2. By twisting the signal core group, ground core, and power core together into an auxiliary cable core, the signal core group, ground core, and power core share the stress when the DC charging cable is bent, significantly reducing the damage to the signal core and lowering the risk of core breakage within the signal core group. The positive, negative, and auxiliary cable cores are of the same size; therefore, the intermediate cable body is formed by twisting five identical but different types of cable cores. This ensures a symmetrical overall structure and even stress distribution within the intermediate cable, resulting in a more rational internal layout. This further reduces the risk of breakage in the smaller diameter signal cores and the larger diameter copper wires in the positive and negative wires after prolonged bending, thus guaranteeing the service life and performance of the DC charging cable.

[0023] 3. By filling the central gap of the intermediate cable body with an elastic filler, and having the elastic filler conform to the positive, negative, and auxiliary cable cores with an arc-shaped surface, the elastic filler can support the central area of ​​the intermediate cable body. When the DC charging cable is bent, the elastic filler can bend along with the intermediate cable body, thus bearing most of the bending force, reducing the stress on the intermediate cable body, and lowering the risk of signal core breakage. Simultaneously, the elastic filler can twist along with the intermediate cable body, ensuring that even if the DC charging cable is used in a bent state for a long time, the conductors in the positive and negative cable cores will not deform significantly, thus ensuring the safety of the DC charging cable. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the DC charging cable provided by this utility model;

[0025] Figure 2 This is a schematic flowchart illustrating the preparation method of the DC charging cable provided by this utility model.

[0026] In the picture:

[0027] 1. Intermediate cable core; 11. Positive cable core; 12. Negative cable core; 13. Auxiliary cable core; 131. Signal core group; 1311. Shielded signal wire; 1312. Unshielded signal wire; 132. Ground core; 133. Power core;

[0028] 2. Elastic filler; 3. Wrapping layer; 4. Outer protective layer; 5. Aramid rope. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0030] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0031] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0032] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0033] like Figure 1As shown, this embodiment provides a DC charging cable, including an intermediate conductor 1, an elastic filler 2, a wrapping layer 3, and an outer sheath 4. The intermediate conductor 1 includes two positive cable cores 11, two negative cable cores 12, and an auxiliary cable core 13, all of the same size and twisted together. The auxiliary cable core 13 includes a twisted signal core group 131, a ground core 132, and a power core 133. By splitting the existing single positive wire into two positive cable cores 11 and the existing single negative wire into two negative cable cores 12, at the bend of the DC charging cable, compared to the existing single positive and single negative wire structure, the stress on the positive cable cores 11 and negative cable cores 12 is more evenly distributed, significantly reducing the stress on the positive cable cores 11 and negative cable cores 12 when the DC charging cable is bent, thus reducing the risk of breakage of the positive cable cores 11 and negative cable cores 12. The signal core group 131, ground core 132, and power core 133 are twisted together to form the auxiliary cable core 13. When the DC charging cable is bent, the signal core group 131, ground core 132, and power core 133 share the stress, significantly reducing the damage to the signal cores and the risk of core breakage within the signal core group 131. The positive cable core 11, negative cable core 12, and auxiliary cable core 13 are of the same size. Therefore, the intermediate cable body 1 is formed by twisting five cable cores of the same size but different types. This ensures that the overall structure of the intermediate cable body 1 is symmetrical and the stress is evenly distributed, making the internal layout of the DC charging cable relatively reasonable. This further reduces the risk of breakage of the smaller diameter signal cores and the larger diameter copper wires inside the positive and negative cables after long-term bending, thus ensuring the service life and performance of the DC charging cable.

[0034] The intermediate cable body 1 has a central gap, and the elastic filler 2 fills and is placed in the central gap. The elastic filler 2 fits the positive cable core 11, negative cable core 12, and auxiliary cable core 13 with an arc-shaped surface. The elastic filler 2 can support the central area of ​​the intermediate cable body 1. When the DC charging cable is bent, the elastic filler 2 can bend with the intermediate cable body 1 to bear most of the force. The elastic filler 2 can effectively reduce the force on the intermediate cable body 1 and reduce the risk of signal core breakage when the DC charging cable is bent. At the same time, when the DC charging cable is twisted, the elastic filler 2 can also twist with the intermediate cable body 1 to reduce the deformation of the positive cable core 11, negative cable core 12, and auxiliary cable core 13 in the intermediate cable body 1. Even if the DC charging cable is used in a bent state for a long time, the conductors in the positive cable core 11 and negative cable core 12 will not deform significantly, thus ensuring the safety of the DC charging cable. The wrapping layer 3 conforms to the outer periphery of the intermediate wire body 1, and the outer sheath 4 conforms to the outer periphery of the wrapping layer 3. This makes the intermediate wire body 1 and the elastic filler 2 more compact, further reducing the stress and deformation of the intermediate wire body 1 when the DC charging cable is bent and twisted, thus improving the service life and safety of the DC charging cable.

[0035] In this embodiment, the elastic filler 2 can be a thermoplastic elastomer, a polyolefin elastomer, or a synthetic rubber.

[0036] In this embodiment, lubricant is applied to the outer periphery of the positive electrode core 11, the negative electrode core 12, the auxiliary core 13, and the elastic filler 2. This prevents friction between the positive electrode core 11, the negative electrode core 12, the auxiliary core 13, and the elastic filler 2 when the intermediate wire 1 and the elastic filler 2 are bent. This improves the conformability of the elastic filler 2 and the intermediate wire 1 when the DC charging cable is bent, further enhancing the service life and safety of the DC charging cable.

[0037] Preferably, the elastic filler 2 has an aramid rope 5 at its center. The aramid rope 5 improves the tensile strength of the elastic filler 2. Since the elastic filler 2 remains straight when twisted with the intermediate wire 1, and the intermediate wire 1 is spirally wound around the elastic filler 2, when the DC charging cable is bent and pulled, the aramid rope 5 at the center of the elastic filler 2 is subjected to tension before the intermediate wire 1, reducing the stress on the intermediate wire 1. Therefore, the aramid rope 5 also improves the tensile strength of the intermediate wire 1, further reducing the risk of breakage during dragging and extending the service life of the DC charging cable. In this embodiment, paraffin oil or talcum powder can be used as the lubricant; no specific limitation is made.

[0038] In this embodiment, the positive electrode core 11 includes a positive conductor and a first insulating layer, and the negative electrode core 12 includes a negative conductor and a second insulating layer. Both the positive and negative conductors are of type 6 conductor. Type 6 conductors are highly flexible, ensuring that the positive and negative electrode cores 11 and 12 can bend at a sufficient angle, further reducing the risk of breakage when the DC charging cable undergoes significant bending. The requirements for Type 6 conductors can be found in GB / T3956-2008, and will not be elaborated upon here.

[0039] Furthermore, the first insulation layer is red, and the second insulation layer is black, making it easier for workers to distinguish between the positive cable core 11 and the negative cable core 12, facilitating subsequent assembly of the charging pile, DC charging cable, and charging gun. The ends of the two positive cable cores 11 connected to the charging gun and the ends connected to the charging pile are crimped together using terminals to form a positive bus. Similarly, the ends of the two negative cable cores 12 connected to the charging gun and the ends connected to the charging pile are crimped together using terminals to form a negative bus. This ensures the DC charging cable's ability to carry high currents. In the cable manufacturing industry, terminals are standard components, so no further restrictions are imposed here.

[0040] For example, the signal core assembly 131 includes a shielded signal core 1311 and an unshielded signal core 1312. The shielded signal core 1311 is formed by twisting multiple shielded signal cores together, and the unshielded signal core 1312 is formed by twisting multiple unshielded signal cores together. Because the shielded and unshielded signal cores have relatively small diameters (i.e., thinner), twisting multiple shielded signal cores together to form the shielded signal core 1311 reduces the risk of breakage due to repeated bending of the DC charging cable. Similarly, twisting multiple unshielded signal cores together to form the unshielded signal core 1312 reduces the risk of breakage due to repeated bending of the DC charging cable, thus improving the design rationality of the DC charging cable. Each shielded signal core is surrounded by a metal braided layer to improve the signal transmission stability of the shielded signal core 1311. The metal braided layer is formed by braiding copper wire, with a braiding density of not less than 80%.

[0041] Furthermore, the twist ratio of both the shielded and unshielded signal cores is 9–12. Because the shielded and unshielded signal cores have relatively small diameters, a twist ratio of 9–12 ensures that the shielded signal cores are twisted together without breaking, thus improving the rationality of the twisting process. Similarly, a twist ratio of 9–12 also ensures that the unshielded signal cores are twisted together without breaking.

[0042] In this embodiment, the outer sheath 4 is made of polyurethane. Polyurethane has high strength, wear resistance, corrosion resistance, flame retardancy, and environmental friendliness, giving the DC charging cable resistance to compression, friction, and acid and alkali corrosion, enabling its application in a wider range of scenarios. Simultaneously, it also provides flame retardancy, improving safety during use. Furthermore, the outer sheath 4 does not produce toxic substances when burned, ensuring environmental safety.

[0043] In this embodiment, the elastic filler 2 and the intermediate wire 1 are twisted together to further improve the conformability of the elastic filler 2 and the intermediate wire 1, reducing the stress and twisting degree of the intermediate wire 1 when the DC charging cable is bent. The twisting pitch ratio of the intermediate wire 1 and the elastic filler 2 is less than or equal to 16, thus preventing the intermediate wire 1 and the elastic filler 2 from being twisted too tightly, which would affect the bending resistance of the DC charging cable and the user experience of the vehicle owner.

[0044] The DC charging cable provided in this embodiment, after undergoing 30,000 110° bending tests with a charging gun installed, did not exhibit any problems such as bulging, cracking, twisting, or breakage, and can still be used normally.

[0045] like Figure 2 As shown in the figure, this embodiment provides a method for preparing a DC charging cable, which is used to prepare the above-mentioned DC charging cable. The method for preparing the DC charging cable includes the following steps:

[0046] Step 1: Twist the signal core group 131, the ground core 132 and the power core 133 together to form the auxiliary cable core 13.

[0047] Step 2: Twist the auxiliary cable core 13, the two positive cable cores 11, and the two negative cable cores 12 together to form the intermediate cable body 1.

[0048] Step 3: Process the shape of the elastic filler according to the shape of the center gap of the intermediate line body 1, so that the processed elastic filler 2 is consistent with the shape of the center gap, and fill the center gap with the processed elastic filler 2.

[0049] Step 4: Wrap the outer periphery of the intermediate line body 1 with a wrapping layer 3.

[0050] Step 5: Extrude the outer protective material around the outer periphery of the wrapping layer 3 to form an outer protective layer 4 that conforms to the shape of the wrapping layer 3.

[0051] Furthermore, step 30 is included between step 3 and step 4:

[0052] Lubricant is added between the positive electrode core 11, the negative electrode core 12, the auxiliary core 13 and the elastic filler 2.

[0053] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make various obvious changes, readjustments, and substitutions without departing from the protection scope of this utility model. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A DC charging cable, characterized in that, include: The intermediate cable body (1) includes two positive cable cores (11) of the same size and twisted together, two negative cable cores (12) and an auxiliary cable core (13). The auxiliary cable core (13) includes a signal core group (131), a ground core (132) and a power core (133) twisted together. The intermediate cable body (1) has a center gap. An elastic filler (2) is placed in the central gap, and the elastic filler (2) is attached to the positive pole cable core (11), the negative pole cable core (12) and the auxiliary cable core (13) with an arc-shaped curved surface; A wrapping layer (3) is formed to cover the outer periphery of the intermediate line body (1); Outer protective layer (4) conformally covers the outer periphery of the wrapping layer (3).

2. The DC charging cable according to claim 1, characterized in that, The outer periphery of the positive electrode core (11), the outer periphery of the negative electrode core (12), the outer periphery of the auxiliary core (13), and the outer periphery of the elastic filler (2) are all coated with lubricant.

3. The DC charging cable according to claim 1, characterized in that, An aramid rope (5) is disposed at the center of the elastic filler (2).

4. The DC charging cable according to claim 1, characterized in that, The positive electrode core (11) includes a positive electrode conductor and a first insulation layer, and the negative electrode core (12) includes a negative electrode conductor and a second insulation layer. The positive electrode conductor and the negative electrode conductor are both type 6 conductors.

5. The DC charging cable according to claim 4, characterized in that, The first insulating layer is red, and the second insulating layer is black.

6. The DC charging cable according to claim 1, characterized in that, The signal core assembly (131) includes a shielded signal core (1311) and an unshielded signal core (1312). The shielded signal core (1311) is formed by twisting together multiple shielded signal cores, and the unshielded signal core (1312) is formed by twisting together multiple unshielded signal cores. The outer periphery of each shielded signal core is covered with a metal braided layer.

7. The DC charging cable according to claim 6, characterized in that, The twist ratio of the multiple shielded signal cores and the multiple unshielded signal cores is 9 to 12.

8. The DC charging cable according to claim 1, characterized in that, The outer protective layer (4) is made of polyurethane.

9. The DC charging cable according to claim 1, characterized in that, The elastic filler (2) is twisted together with the intermediate wire (1), and the twisting diameter ratio of the intermediate wire (1) and the elastic filler (2) is less than or equal to 16.

10. The DC charging cable according to claim 1, characterized in that, The elastic filler (2) is made of thermoplastic elastomer or synthetic rubber.

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