Liquid-cooled cable assembly for high-power charging gun

Abstract

The utility model relates to new energy electric automobile field discloses a kind of liquid cooling cable assembly for high-power charging gun, including cable main body, installation lining and stake end connection terminal, several liquid cooling pipes are arranged in cable main body, power conductor is arranged in liquid cooling pipe and has interspace;The one end of installation lining is provided with DC terminal, DC terminal is welded with power conductor and is conducted through;The outside of stake end connection terminal is connected with copper bar in charging pile, the inside of stake end connection terminal is welded with power conductor and is conducted through.The above-mentioned liquid cooling cable assembly for high-power charging gun forms liquid cooling passage from DC terminal, liquid cooling pipe to stake end connection terminal, and the heat dissipation effect is effectively improved, meets the high-power charging requirement, in addition, using the structure that liquid cooling pipe is sleeved in the outer power conductor, can substantially reduce the outer diameter size, reduces the weight of high-power charging gun cable, difficult to bend, storage and inconvenient operation, there is torsional stress and other problems, more convenient for user use.

Description

Technical Field

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

[0002] As the battery packs of electric vehicles carry increasingly larger capacities, the required charging power also increases. Increasing charging power not only requires raising the voltage platform of the electric vehicle but also necessitates a significant increase in charging current to achieve megawatt-level high-power fast charging. Increasing the charging current requires larger cable cross-sections and the introduction of heat dissipation structures, but this also makes the cables thicker and heavier, making charging operations more difficult. Currently available liquid-cooled cables generally suffer from problems such as large outer diameter, heavy weight, large bending radius, difficulty in storage, and torsional stress caused by knots when suspended or dragged on the ground, affecting the user experience. Utility Model Content

[0003] Based on the above, the purpose of this utility model is to provide a liquid-cooled cable assembly for a high-power charging gun, which ensures heat dissipation while reducing the outer diameter and weight of the cable.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A liquid-cooled cable assembly for a high-power charging gun includes a cable body, an mounting liner, and terminal blocks at the charging end, wherein:

[0006] One end of the cable body extends to the charging gun head, and the other end of the cable body extends to the charging pile. Several liquid cooling pipes are installed in the cable body, and power conductors are installed in the liquid cooling pipes with gaps.

[0007] The mounting liner is installed inside the charging gun head. One end of the mounting liner is equipped with a sealing water nozzle that is sealed to the first end of the liquid cooling pipe. The other end of the mounting liner is equipped with a DC terminal for cooperating with the vehicle-side charging socket. The DC terminal is welded to the power conductor for conduction.

[0008] One end of the terminal block is sealed to the second end of the liquid cooling pipe, and the other end of the terminal block is connected to the input and output water nozzles through a fixed hose. The input and output water nozzles are connected to the heat dissipation assembly inside the charging pile. The outside of the terminal block is connected to the copper busbar inside the charging pile, and the inside of the terminal block is welded to the power conductor for conduction.

[0009] As an optional solution, a liquid-cooled cavity is provided in the mounting liner, and sealing rings are respectively provided on the DC terminal and the sealing water nozzle to ensure the sealing of the liquid-cooled cavity.

[0010] As an alternative, the head end of the DC terminal is exposed to the mounting liner and is provided with a finger-proof plug at the head end, while the tail end of the DC terminal is located in the liquid-cooled cavity and is provided with a first flat portion for soldering to the power conductor.

[0011] As an alternative, the exterior of the sealing nozzle is fixed to the mounting liner by bolts, and the end of the sealing nozzle located outside the liquid cooling cavity is provided with a first pagoda joint that is interference-fitted with the liquid cooling pipe.

[0012] As an alternative, there are two DC terminals, with two independent liquid-cooled cavities corresponding to the two different polarities of the DC terminals in the mounting liner.

[0013] As an alternative, there are two DC terminals. The mounting liner has two interconnected liquid-cooled cavities corresponding to the two DC terminals of different polarities. The coolant in the liquid-cooled cavities has insulating properties.

[0014] As an alternative, only one power conductor is installed in each liquid cooling pipe, and at least one is installed for each liquid cooling cavity. The sealing water nozzle is installed for each power conductor or only one power conductor of the same polarity is installed. The terminal block is installed for each power conductor or only one power conductor of the same polarity is installed.

[0015] As an alternative, the first end of the pile terminal is provided with a second pagoda connector that is interference-fitted with the liquid cooling pipe, the second end of the pile terminal is provided with a third pagoda connector that is interference-fitted with the fixed hose, and the end of the second end extends out to form a second flat portion that is welded to the power conductor. The outside of the pile terminal is provided with a fixing hole for connecting to the copper busbar of the charging pile.

[0016] As an optional solution, one end of the input / output water nozzle is equipped with a fourth pagoda connector that is interference-fitted with the fixed hose, and the other end of the input / output water nozzle is equipped with a fifth pagoda connector that connects to the heat dissipation assembly inside the charging pile.

[0017] As an optional solution, clamps are provided at both ends of the liquid cooling pipe and at both ends of the fixed hose.

[0018] The beneficial effects of this utility model are:

[0019] The liquid-cooled cable assembly for this high-power charging gun forms a liquid-cooled path from the DC terminal, liquid-cooled pipe to the terminal block, effectively improving heat dissipation and meeting the requirements of high-power charging. In addition, the structure of the liquid-cooled pipe being sleeved outside the power conductor can significantly reduce the outer diameter, reducing problems such as the large weight of the high-power charging gun cable, difficulty in bending, inconvenience in storage and operation, and torsional stress, making it more convenient for users. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a liquid-cooled cable assembly for a high-power charging gun provided in an embodiment of this utility model;

[0021] Figure 2 This is an end face view of the mounting liner in the liquid-cooled cable assembly for a high-power charging gun provided in this embodiment of the utility model;

[0022] Figure 3 yes Figure 2 Sectional view of AA in the middle;

[0023] Figure 4 yes Figure 2 Cross-sectional view of the middle section (BB);

[0024] Figure 5 This is a schematic diagram of the terminal block of the liquid-cooled cable assembly for a high-power charging gun provided in this embodiment of the utility model.

[0025] Figure 6 yes Figure 5 CC cross-section view.

[0026] In the attached image:

[0027] 1. Cable body; 11. Liquid cooling pipe; 12. Power conductor; 13. Gap;

[0028] 2. Install the inner lining; 21. Liquid-cooled cavity;

[0029] 3. Pile end terminal; 31. Second pagoda connector; 32. Third pagoda connector; 33. Second flat part; 34. Fixing hole;

[0030] 4. Sealing faucet; 41. First pagoda connector;

[0031] 5. Clamps;

[0032] 6. DC terminal; 61. Sealing ring; 62. Anti-touch finger plug; 63. First flat part;

[0033] 7. Secure the flexible hose;

[0034] 8. Input and output water nozzles; 81. Fourth pagoda connector; 82. Fifth pagoda connector. Detailed Implementation

[0035] 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.

[0036] 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.

[0037] 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.

[0038] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of description and simplification of operation, and are not intended to 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.

[0039] Furthermore, the terms "first" and "second" are merely used to distinguish between different terms in description and do not have any special meaning.

[0040] Please see Figures 1 to 6 As shown, this embodiment provides a liquid-cooled cable assembly for a high-power charging gun, including a cable body 1, a mounting liner 2, and terminal blocks 3, wherein:

[0041] One end of the cable body 1 extends to the charging gun head, and the other end of the cable body 1 extends to the charging pile. Several liquid cooling pipes 11 are installed in the cable body 1, and power conductors 12 are installed in the liquid cooling pipes 11 with gaps 13.

[0042] The mounting liner 2 is installed inside the charging gun head. One end of the mounting liner 2 is provided with a sealing water nozzle 4 that is sealed and connected to the first end of the liquid cooling pipe 11. The other end of the mounting liner 2 is provided with a DC terminal 6 for cooperating with the vehicle-side charging socket. The DC terminal 6 is welded and connected to the power conductor 12.

[0043] One end of the terminal block 3 is sealed to the second end of the liquid cooling pipe 11. The other end of the terminal block 3 is connected to the input / output water nozzle 8 through the fixed hose 7. The input / output water nozzle 8 is connected to the heat dissipation assembly inside the charging pile. The outside of the terminal block 3 is connected to the copper busbar inside the charging pile. The inside of the terminal block 3 is welded to the power conductor 12 for conduction.

[0044] This creates a liquid-cooled path from DC terminal 6 and liquid-cooled pipe 11 to terminal 3 at the charging pile end, effectively improving heat dissipation and meeting the requirements of high-power charging. Furthermore, the structure of the liquid-cooled pipe 11 being sleeved outside the power conductor 12 significantly reduces the outer diameter, mitigating problems such as the heavy weight, difficulty in bending, inconvenient storage and operation, and torsional stress associated with high-power charging gun cables, making them more convenient for users.

[0045] In at least one embodiment, a liquid-cooled cavity 21 is provided in the mounting liner 2, and sealing rings 61 for ensuring the sealing of the liquid-cooled cavity 21 are respectively provided on the DC terminal 6 and the sealing water nozzle 4.

[0046] The liner 2 here mainly serves to provide electrical insulation and isolation, contain coolant to form a liquid cooling passage, install and fix the DC terminal 6, and seal the water nozzle 4.

[0047] For details, see Figure 3 and Figure 4 The head end of the DC terminal 6 is cylindrical and protrudes from the mounting liner 2, and the head end is provided with a finger-proof plug 62. The tail end of the DC terminal 6 is located in the liquid-cooled cavity 21 and the tail end is provided with a first flat part 63 for welding with the power conductor 12 to ensure reliable electrical conduction.

[0048] The outer part of the sealing water nozzle 4 is fixed to the inner liner 2 by bolts. The end of the sealing water nozzle 4 located outside the liquid cooling cavity 21 is provided with a first pagoda connector 41 that is interference-fitted with the liquid cooling pipe 11. The inner diameter of the first pagoda connector 41 is used to accommodate the power conductor 12 and coolant entering the liquid cooling cavity 21, and the outer diameter of the first pagoda connector 41 is used to seal and connect with the liquid cooling pipe 11.

[0049] In some embodiments, there are two DC terminals 6 (DC+ and DC- respectively), and the mounting liner 2 is provided with two independent liquid-cooled cavities 21 corresponding to the two DC terminals 6 of different polarities. The two liquid-cooled cavities 21 do not affect each other, so as to independently cool DC+ and DC-.

[0050] In other embodiments, two DC terminals 6 are provided. The mounting liner 2 has two interconnected liquid-cooled cavities 21 corresponding to the two DC terminals 6 of different polarities, or it is a single liquid-cooled cavity 21. The coolant in the liquid-cooled cavity 21 has insulating properties. The insulating coolant can prevent short circuits and can reduce the arrangement of liquid-cooled pipes 11, sealing nozzles 4, and terminal blocks 3, thus simplifying the cable structure.

[0051] Specifically, each liquid cooling pipe 11 has only one power conductor 12, and each liquid cooling cavity 21 has at least one liquid cooling pipe 11. Each power conductor 12 has one sealing water nozzle 4, or only one power conductor 12 of the same polarity is provided. Each power conductor 12 has one terminal block 3, or only one power conductor 12 of the same polarity is provided.

[0052] The example structure here consists of two liquid-cooled cavities 21, each with two liquid-cooled pipes 11, for a total of four liquid-cooled pipes 11 and four power conductors 12. Two power conductors 12 of the same polarity share a sealing water nozzle 4 and are each equipped with a terminal block 3.

[0053] Combination Figure 1 As shown, one end of liquid cooling pipe 11 (a#), one end of liquid cooling pipe 11 (b#), one end of liquid cooling pipe 11 (c#), and one end of liquid cooling pipe 11 (d#) are each connected to a terminal block 3. The other end of liquid cooling pipe 11 (a#) and the other end of liquid cooling pipe 11 (b#) are connected to a sealing water nozzle 4 and then to a liquid cooling cavity 21 where the inner liner 2 is installed. This forms a liquid cooling path from liquid cooling pipe 11 (a#) into liquid cooling cavity 21 and then from liquid cooling cavity 21 to liquid cooling pipe 11 (b#). The other end of liquid cooling pipe 11 (c#) and the other end of liquid cooling pipe 11 (d#) are connected to another sealing water nozzle 4 and then to another liquid cooling cavity 21 where the inner liner 2 is installed. This forms another liquid cooling path from liquid cooling pipe 11 (c#) into liquid cooling cavity 21 and then from liquid cooling cavity 21 to liquid cooling pipe 11 (d#). The two liquid cooling paths are independent of each other, realizing a two-in, two-out circulation of coolant.

[0054] In at least one embodiment, see details. Figure 6 The first end of the pile terminal 3 is provided with a second pagoda connector 31 that is interference-fitted with the liquid cooling pipe 11. The second end of the pile terminal 3 is provided with a third pagoda connector 32 that is interference-fitted with the fixed hose 7, and the end of the second end extends out to form a second flat portion 33 that is welded to the power conductor 12. The outside of the pile terminal 3 is provided with a fixing hole 34 for connecting to the copper busbar of the charging pile.

[0055] The terminal block 3 at this point mainly serves to receive the coolant for the entire circuit and connect to the copper busbar of the charging pile. The inner diameter of the second pagoda connector 31 is used to accommodate the power conductor 12 and the coolant, and the outer diameter of the second pagoda connector 31 is used to seal and connect with the liquid cooling pipe 11. The second flat part 33 is used to ensure reliable electrical conduction between the terminal block 3 and the power conductor 12. The terminal block 3 is electrically connected to the copper busbar of the charging pile by passing a conductive connector through the fixing hole 34.

[0056] In some embodiments, one end of the input / output water nozzle 8 is provided with a fourth pagoda connector 81 that is interference-fitted with the fixed hose 7, and the other end of the input / output water nozzle 8 is provided with a fifth pagoda connector 82 that is connected to the heat dissipation assembly in the charging pile.

[0057] In some embodiments, clamps 5 are provided at both ends of the liquid cooling pipe 11 and at both ends of the fixed hose 7 to further ensure the sealing of the connection and prevent coolant leakage.

[0058] In summary, this liquid-cooled cable assembly for high-power charging guns has the following advantages:

[0059] 1) A liquid cooling path is formed from DC terminal 6, liquid cooling pipe 11 to pile terminal 3. The coolant flows out from the heat dissipation assembly of the charging pile, passes through a liquid cooling path to the liquid cooling cavity 21 to cool the DC terminal 6, and then flows back to the heat dissipation assembly through another liquid cooling path. The heat dissipation effect is obvious.

[0060] 2) By adopting the water-coated copper (liquid cooling pipe 11 is set outside the power conductor 12) scheme, the outer diameter of the cable body 1 can be greatly reduced, which solves the problems of heavy weight and difficulty in bending of high-power charging gun cables, as well as the difficulties in operation and storage. At the same time, the bending radius is reduced, which solves the problems of large bending radius of round cables, large space occupation, and torsional stress caused by cable knots when the round cables are suspended or dragged on the ground during the charging process.

[0061] 3) The connection between the charging pile terminal 3 and the heat dissipation assembly of the charging pile is made more flexible by fixing the flexible hose 7;

[0062] 4) The structure is simplified, which improves assembly efficiency and reduces the failure rate.

[0063] 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 liquid-cooled cable assembly for a high-power charging gun, characterized in that, Includes the cable body (1), mounting liner (2), and terminal block (3), wherein: One end of the cable body (1) extends to the charging gun head, and the other end of the cable body (1) extends to the charging pile. Several liquid cooling pipes (11) are installed in the cable body (1), and power conductors (12) are installed in the liquid cooling pipes (11) with gaps (13). The mounting liner (2) is disposed inside the charging gun head. One end of the mounting liner (2) is provided with a sealing water nozzle (4) that is sealed and connected to the first end of the liquid cooling pipe (11). The other end of the mounting liner (2) is provided with a DC terminal (6) for cooperating with the vehicle-side charging socket. The DC terminal (6) is welded and connected to the power conductor (12). One end of the terminal block (3) is sealed to the second end of the liquid cooling pipe (11), and the other end of the terminal block (3) is connected to the input / output water nozzle (8) through the fixed hose (7). The input / output water nozzle (8) is connected to the heat dissipation assembly inside the charging pile. The outside of the terminal block (3) is connected to the copper busbar inside the charging pile, and the inside of the terminal block (3) is welded to the power conductor (12) for conduction.

2. The liquid-cooled cable assembly for a high-power charging gun according to claim 1, characterized in that, The mounting liner (2) has a liquid cooling cavity (21) and the DC terminal (6) and the sealing water nozzle (4) are respectively provided with sealing rings (61) to ensure the sealing of the liquid cooling cavity (21).

3. The liquid-cooled cable assembly for a high-power charging gun according to claim 2, characterized in that, The head end of the DC terminal (6) is exposed inside the mounting liner (2) and is provided with a finger-proof plug (62) at the head end. The tail end of the DC terminal (6) is located in the liquid-cooled cavity (21) and is provided with a first flat portion (63) for welding to the power conductor (12).

4. The liquid-cooled cable assembly for a high-power charging gun according to claim 2, characterized in that, The exterior of the sealing water nozzle (4) is fixed to the mounting liner (2) by bolts. The end of the sealing water nozzle (4) located outside the liquid cooling cavity (21) is provided with a first pagoda connector (41) that is interference-fitted with the liquid cooling pipe (11).

5. The liquid-cooled cable assembly for a high-power charging gun according to claim 2, characterized in that, The DC terminal (6) is provided in two forms, and the mounting liner (2) is provided with two independent liquid cooling cavities (21) corresponding to the two DC terminals (6) of different polarities.

6. The liquid-cooled cable assembly for a high-power charging gun according to claim 2, characterized in that, Two DC terminals (6) are provided. The mounting liner (2) has two interconnected liquid-cooled cavities (21) corresponding to the two DC terminals (6) of different polarities. The coolant in the liquid-cooled cavity (21) has insulating properties.

7. The liquid-cooled cable assembly for a high-power charging gun according to claim 5 or 6, characterized in that, Only one power conductor (12) is installed in each of the liquid cooling pipes (11), and at least one liquid cooling pipe (11) is provided for each of the liquid cooling cavities (21). The sealing water nozzle (4) is provided for each of the power conductors (12) or only one power conductor (12) of the same polarity is provided. The terminal block (3) is provided for each of the power conductors (12) or only one power conductor (12) of the same polarity is provided.

8. The liquid-cooled cable assembly for a high-power charging gun according to claim 1, characterized in that, The first end of the pile terminal (3) is provided with a second pagoda connector (31) that is interference-fitted with the liquid cooling pipe (11). The second end of the pile terminal (3) is provided with a third pagoda connector (32) that is interference-fitted with the fixed hose (7), and the end of the second end extends out to form a second flat portion (33) that is welded to the power conductor (12). The outside of the pile terminal (3) is provided with a fixing hole (34) for connecting to the copper busbar of the charging pile.

9. The liquid-cooled cable assembly for a high-power charging gun according to claim 1, characterized in that, One end of the input / output water nozzle (8) is provided with a fourth pagoda connector (81) that is interference-fitted with the fixed hose (7), and the other end of the input / output water nozzle (8) is provided with a fifth pagoda connector (82) that is connected to the heat dissipation assembly in the charging pile.

10. The liquid-cooled cable assembly for a high-power charging gun according to claim 1, characterized in that, Clamps (5) are provided at both ends of the liquid cooling pipe (11) and at both ends of the fixed hose (7).

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