Liquid-cooled lightweight charging gun

Abstract

The utility model discloses a liquid cooling light weight charging gun belongs to new energy automobile field, including the gun head and copper core cable, copper core cable and gun head electric connection, still include the wire, the wire includes cable, insulating layer, shielding layer, cooling pipe and sheath, the insulating layer is covered in the cable outside, the shielding layer is covered in the insulating layer's outside, the cooling pipe is covered in the shielding layer's outside, the sheath is covered in the cooling pipe's outside, the gun head in fixedly embedded has the cold pressure copper aluminum transition connecting pipe, this scheme can significantly optimize charging gun comprehensive performance through adopting rare earth high -strength aluminum alloy cable technology, in cost control aspect, the novel conductor material can realize overall cost reduction, in light weight design level, the weight reduction of traditional copper cable, its excellent heat conduction characteristic makes cable operating temperature reduction, and the conductivity can be promoted with special alloy formula, reduces more than 5% energy loss while improving the current -carrying capacity.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicles, and more specifically, to a liquid-cooled lightweight charging gun. Background Technology

[0002] The charging gun is the core interface component for transferring electrical energy to the vehicle battery. Currently, most mainstream charging guns on the market use high-purity copper conductors as the cable core material to meet the requirements of high-current transmission.

[0003] However, current copper-core cable-based design schemes have the following significant drawbacks: Copper's high density, coupled with the large conductor cross-sectional area required to carry high currents, significantly increases the overall weight of the charging gun. This not only increases the user's operational burden but also negatively impacts the user experience. Furthermore, copper, as a vital strategic metal resource, is relatively expensive, constituting a major portion of the charging gun's material cost. This high cost limits the widespread adoption and promotion of charging infrastructure. Simultaneously, copper conductors are prone to fatigue damage under repeated bending, insertion, and removal stresses, leading to fractures or increased contact resistance. Additionally, prolonged operation and heat generation accelerate the aging of insulation materials. These factors collectively result in traditional copper-core charging guns failing to meet the ever-increasing durability requirements. Moreover, although copper conductors have low resistance, they still generate significant Joule heat loss under high-current, long-distance transmission scenarios. This energy loss not only reduces the overall efficiency of the charging process but also exacerbates cable temperature rise, further impacting safety and lifespan.

[0004] To address this, a liquid-cooled lightweight charging gun is proposed. Utility Model Content

[0005] To address the problems existing in the prior art, the purpose of this utility model is to provide a liquid-cooled lightweight charging gun that can effectively reduce weight, reduce manufacturing costs, extend service life, and improve energy transmission efficiency.

[0006] To solve the above problems, the present invention adopts the following technical solution.

[0007] A liquid-cooled lightweight charging gun includes a gun head and a copper core cable, wherein the copper core cable is electrically connected to the gun head; It also includes wires; The conductor includes a cable, an insulation layer, a shielding layer, a cooling pipe, and a sheath; The insulation layer is sleeved on the outside of the cable; The shielding layer is sleeved on the outside of the insulating layer; The cooling pipe is sleeved outside the shielding layer; The sheath is fitted over the outside of the cooling pipe; The gun head is fixedly embedded with a cold-pressed copper-aluminum transition connecting tube. The copper core cable and the wire are respectively inserted into the two ends of the cold-pressed copper-aluminum transition connecting tube. The wire in the wire is inserted into the cold-pressed copper-aluminum transition connecting tube, and then pressure is applied to the cold-pressed copper-aluminum transition connecting tube to clamp and fix the copper core cable and the wire.

[0008] Furthermore, the cable is a rare-earth high-speed rail aluminum alloy cable; through material innovation and process optimization, the rare-earth high-speed rail aluminum alloy cable comprehensively surpasses traditional copper cables in terms of conductivity, mechanical strength, corrosion resistance, economy, and environmental protection, thus reducing costs.

[0009] Furthermore, the cooling pipe is made of silicon carbide, and the heat conduction effect is improved by using silicon carbide with high thermal conductivity.

[0010] Furthermore, the insulating layer is made of rubber material, which, due to its insulating properties, can separate cables from each other and from the protective layer, thus achieving insulation.

[0011] Furthermore, the cooling pipe has uniformly spaced cavities filled with coolant. Since the coolant is fluid, filling the cavities with coolant allows the heated coolant to flow within the cavities when the charging gun is shaken, mixing the high-temperature coolant with the low-temperature coolant and achieving automatic heat dissipation and cooling.

[0012] Furthermore, the sheath is made of rubber material to protect the internal structure and provide mechanical strength.

[0013] Furthermore, the cavity is evenly distributed circumferentially on the cooling pipe, thereby improving the heat absorption effect of the coolant on the cooling pipe and enabling the cooling pipe to dissipate heat evenly.

[0014] Furthermore, the space between the inner wall of the cooling pipe and the outer wall of the shielding layer is filled with an ultra-light polymer; the ultra-light polymer forms an elastic support layer, which disperses external extrusion and bending stress, avoids local deformation of the thin-walled sheath from damaging the internal core wire, absorbs impact energy, protects the brittle insulation layer, and prevents electromagnetic vibration from causing internal frictional heat generation during high-power charging.

[0015] Furthermore, the cavity has uniformly distributed protrusions on its sidewalls, thereby increasing the surface area of ​​the cavity and improving the heat conduction effect.

[0016] Furthermore, the surface of the insulation layer is mirror-like, thereby reducing the frictional force on the insulation layer when the copper core cable is bent, and preventing damage to the insulation layer. Compared with the prior art, the beneficial effects of this utility model are as follows: (1) This solution can reduce the cost and weight of the charging gun by using rare earth high-speed rail aluminum alloy cable.

[0017] (2) This solution can improve the heat dissipation of the cable by setting up cooling pipes, effectively reduce energy consumption and increase service life. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a cross-sectional view of the gun head of this utility model; Figure 3 This is a cross-sectional view of the conductor of this utility model; Figure 4 This is a cross-sectional view of the cooling pipe of this utility model.

[0019] Explanation of the labels in the diagram: 1. Gun head; 2. Copper core cable; 3. Conductor; 301. Cable; 302. Insulation layer; 303. Shielding layer; 304. Sheath; 305. Cooling pipe; 4. Cold-pressed copper-aluminum transition connecting pipe; 5. Cavity; 6. Ultra-light polymer; 7. Bump. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0021] Please see Figures 1 to 4 A liquid-cooled lightweight charging gun includes a gun head 1 and a copper core cable 2, wherein the copper core cable 2 is electrically connected to the gun head 1. It also includes wire 3; The conductor 3 includes a cable 301, an insulation layer 302, a shielding layer 303, a cooling pipe 305, and a sheath 304; The insulating layer 302 is sleeved on the outside of the cable 301; The shielding layer 303 is sleeved on the outside of the insulating layer 302; The cooling pipe 305 is sleeved on the outside of the shielding layer 303; The sheath 304 is fitted over the outside of the cooling pipe 305; The gun head 1 is fixedly embedded with a cold-pressed copper-aluminum transition connecting tube 4. The copper core cable 2 and the wire 3 are respectively inserted into the two ends of the cold-pressed copper-aluminum transition connecting tube 4. The cable 301 in the wire 3 is inserted into the cold-pressed copper-aluminum transition connecting tube 4. Then, pressure is applied to the cold-pressed copper-aluminum transition connecting tube 4 to clamp and fix the copper core cable 2 and the wire 3.

[0022] like Figure 3 As shown, the cable 301 is a rare earth high-speed rail aluminum alloy cable; through material innovation and process optimization, the rare earth high-speed rail aluminum alloy cable surpasses traditional copper cables in terms of conductivity, mechanical strength, corrosion resistance, economy and environmental protection, thus reducing costs.

[0023] like Figure 3 As shown, the cooling pipe 305 is made of silicon carbide. By utilizing silicon carbide, which has high thermal conductivity, the heat conduction effect of the cooling pipe 305 is improved.

[0024] like Figure 3 As shown, the insulating layer 302 is made of rubber material. Since rubber material has insulating properties, it can separate cables 301 from each other and cables 301 from the protective layer, thus achieving insulation.

[0025] like Figure 3 , Figure 4 As shown, the cooling pipe 305 has uniformly opened cavities 5, and the cavities 5 are filled with coolant. Since the coolant can flow, by filling the cavity 5 with coolant, the heated coolant can flow in the cavity 5 when the charging gun is shaken, so that the high-temperature coolant mixes with the low-temperature coolant, thereby achieving the function of automatic heat dissipation and cooling.

[0026] like Figure 3 As shown, the sheath 304 is made of rubber material and is used to protect the internal structure and provide mechanical strength.

[0027] like Figure 3 As shown, the cavity 5 is evenly distributed circumferentially on the cooling pipe 305, thereby improving the heat absorption effect of the coolant on the cooling pipe 305 and making the cooling pipe 305 dissipate heat evenly.

[0028] like Figure 3 As shown, the space between the inner wall of the cooling pipe 305 and the outer wall of the shielding layer 303 is filled with ultra-light polymer 6; the ultra-light polymer forms an elastic support layer, which disperses external extrusion and bending stress, avoids local deformation of the thin-walled sheath from damaging the internal core wire, absorbs impact energy, protects the brittle insulation layer, and prevents electromagnetic vibration from causing internal frictional heat generation during high-power charging.

[0029] like Figure 4As shown, protrusions 7 are uniformly provided on the side wall of the cavity 5, thereby increasing the surface area of ​​the cavity 5 and improving the heat conduction effect.

[0030] like Figure 3 As shown, the surface of the insulation layer 302 is mirror-like, which reduces the frictional force on the insulation layer 302 when the copper core cable 2 is bent, thus preventing the insulation layer 302 from being damaged.

[0031] The above description is merely a preferred embodiment of this utility model; however, the protection scope of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in this utility model, based on the technical solution and its improved concept, should be included within the protection scope of this utility model.

Claims

1. A liquid-cooled lightweight charging gun, comprising a gun head (1) and a copper core cable (2), wherein the copper core cable (2) is electrically connected to the gun head (1); Its features are: It also includes wires (3); The conductor (3) includes a cable (301), an insulation layer (302), a shielding layer (303), a cooling pipe (305), and a sheath (304). The insulating layer (302) is sleeved on the outside of the cable (301); The shielding layer (303) is sleeved on the outside of the insulating layer (302); The cooling pipe is sleeved on the outside of the shielding layer (303); The sheath (304) is fitted over the outside of the cooling pipe (305); The gun head (1) is fixedly embedded with a cold-pressed copper-aluminum transition connecting tube (4), and the copper core cable (2) and the wire (3) are respectively inserted at both ends of the cold-pressed copper-aluminum transition connecting tube (4).

2. The liquid-cooled lightweight charging gun according to claim 1, characterized in that: The cable (301) is a rare earth high-speed rail aluminum alloy cable.

3. The liquid-cooled lightweight charging gun according to claim 1, characterized in that: The cooling pipe (305) is made of silicon carbide.

4. The liquid-cooled lightweight charging gun according to claim 1, characterized in that: The insulating layer (302) is made of rubber material.

5. A liquid-cooled lightweight charging gun according to claim 1, characterized in that: The sheath (304) is made of rubber material.

6. The liquid-cooled lightweight charging gun according to claim 1, characterized in that: The cooling pipe (305) has cavities (5) evenly distributed on it, and the cavities (5) are filled with coolant.

7. A liquid-cooled lightweight charging gun according to claim 6, characterized in that: The cavity (5) is evenly distributed circumferentially on the cooling pipe (305).

8. A liquid-cooled lightweight charging gun according to claim 7, characterized in that: The space between the inner wall of the cooling pipe (305) and the outer wall of the shielding layer (303) is filled with an ultra-light polymer (6).

9. A liquid-cooled lightweight charging gun according to claim 8, characterized in that: The cavity (5) has protrusions (7) evenly distributed on its sidewall.

10. A liquid-cooled lightweight charging gun according to claim 1, characterized in that: The surface of the insulating layer (302) is mirror-like.

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