High-temperature resistant, high-heat dissipation energy storage continuous charge and discharge cable

Abstract

This utility model relates to the field of wire and cable technology, specifically to a high-temperature resistant, high-heat-dissipation, energy-storage continuous charge-discharge cable, comprising: two or three parallel-arranged conductors; an inner sheath layer extruded onto the outer wall of the conductors, wherein the inner sheath layer is configured to conform to the outer contour formed by the parallel-arranged conductors within its cross-section; and an outer sheath layer extruded onto the surface of the inner sheath layer, wherein the outer sheath layer is configured to have two arc surfaces and two planes. This application abandons the circular cable of the prior art, arranging each insulated conductor with an independent metal heat dissipation layer in parallel, and then extruding the entire cable with an outer sheath. This structure allows each conductor to dissipate heat directly through its own heat dissipation layer and the outer sheath, resulting in the shortest heat dissipation path, highest efficiency, and reduced heat accumulation inside the stranding, achieving the shortest and most optimized heat dissipation path.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable technology, and more specifically to a high-temperature resistant, high-heat-dissipation energy storage continuous charge and discharge cable. Background Technology

[0002] As electrochemical energy storage power stations develop towards larger capacity and higher power density, heat management generated by high-current, high-rate continuous charging and discharging between battery clusters has become a pain point in the industry. The DC energy storage cable connecting the battery module and the converter (PCS) serves as the energy transmission channel, and its own heat generation and heat dissipation capabilities directly affect the system's operating efficiency and safety.

[0003] Currently, this type of cable mostly follows the traditional design concept of medium-voltage power cables, adopting a circular stranded structure, with a thick cross-linked polyethylene (XLPE) or ethylene propylene rubber (EPR) insulation layer wrapped around the conductor, and the outermost layer being a polyvinyl chloride (PVC) or thermoplastic polyolefin (TPE) sheath.

[0004] This classic structure performs well in fixed AC power distribution, but its limitations become apparent when applied to the interior of energy storage containers where space is limited, ambient temperature is high, and current changes are drastic: the circular stranded structure tightly wraps the wire core inside, resulting in a long and difficult heat dissipation path from the inside out, which easily leads to heat accumulation in the center and becomes a bottleneck in the system's heat dissipation chain.

[0005] Although the industry has attempted to improve the situation by increasing the conductor cross-sectional area and adding thermally conductive fillers to the sheath, the effects have been limited, and new problems have arisen, such as a significant increase in cable weight, bending radius, and cost. Therefore, there is an urgent need for a new cable design that can optimize the heat dissipation path from a structural perspective and fundamentally reduce the conductor operating temperature. Utility Model Content

[0006] To address the technical problems existing in current charging and discharging cables, this utility model proposes a high-temperature resistant, high-heat-dissipation energy storage continuous charging and discharging cable, comprising:

[0007] Two or three wire cores arranged side by side;

[0008] An inner sheath layer is extruded onto the outer wall of multiple core wires, and the inner sheath layer is constructed to conform to the outer contour formed by the outer contour of the cross-section and the multiple core wires arranged side by side.

[0009] An outer sheath layer is extruded onto the surface of the inner sheath layer. The outer sheath layer is constructed to have two arc surfaces and two planes. The arc surfaces and the surface of the wire core form a first heat dissipation path, and the planes and the surface of the wire core form a second heat dissipation path.

[0010] The wire core includes stranded conductors, insulation layer, fire-resistant layer and thermally conductive layer distributed from the inside to the outside. The inner sheath layer is extruded on the outer wall of the thermally conductive layer. The thermally conductive layer is a composite structure layer composed of a metal thermally conductive layer and a thermally conductive paste layer.

[0011] Preferably, the stranded conductor comprises a multi-layered circular copper wire tightly stranded structure, wherein the copper wire comprises silver-plated or nickel-plated copper wire.

[0012] Preferably, the insulating layer comprises a silicone rubber insulating layer.

[0013] Preferably, the refractory layer includes a mica tape wrapping layer and a glass fiber woven layer.

[0014] Preferably, the thermal conductive paste layer includes a first thermal conductive paste layer coated on the surface of the refractory layer, and the metal thermal conductive layer includes a copper strip covering layer covering the surface of the first thermal conductive paste layer.

[0015] Preferably, the thermal paste layer further includes a second thermal paste layer coated on the surface of the copper strip covering layer.

[0016] Preferably, the inner sheath layer comprises an alkali-free ceramicized silicone rubber extrusion layer.

[0017] Preferably, the outer sheath layer comprises a silicone rubber sheath layer or a highly thermally conductive modified polyolefin sheath layer.

[0018] Preferably, the surface of the plane is provided with heat dissipation grooves, and the heat dissipation grooves and the surface of the wire core form a third heat dissipation path, the length of the third heat dissipation path being less than the length of the second heat dissipation path.

[0019] Preferably, the heat dissipation groove is located at the point where the two wire cores are tangent.

[0020] Compared with the prior art, the advantages of this utility model are:

[0021] This application abandons the circular cable of the prior art and arranges each insulated core with an independent metal heat dissipation layer in parallel, and then extrudes the whole into an outer sheath. This structure allows each core to dissipate heat directly through its own heat dissipation layer and outer sheath, resulting in the shortest heat dissipation path and the highest efficiency. It reduces the heat accumulation inside the twisting and achieves the shortest and most optimized heat dissipation path. At the same time, this structure greatly facilitates the installation in confined spaces. The side-by-side arrangement of positive and negative cores also makes the wiring operation clear at a glance and effectively reduces the risk of installation errors. Attached Figure Description

[0022] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in the various figures may be denoted by the same reference numeral. For clarity, not every component is labeled in each figure. Embodiments of various aspects of the present invention will now be described by way of example and with reference to the accompanying drawings, wherein:

[0023] Figure 1 This is a schematic diagram of the structure of the temperature-resistant, high-heat-dissipation energy storage continuous charge-discharge cable shown in this utility model.

[0024] Figure 2 This is a schematic diagram of the cross-sectional structure of the temperature-resistant, high-heat-dissipation energy storage continuous charge-discharge cable shown in this utility model.

[0025] Figure 3 This is a schematic diagram of the wire core structure shown in this utility model;

[0026] Figure 4 This is a schematic diagram of the cross-sectional structure of the wire core structure shown in this utility model. Detailed Implementation

[0027] To better understand the technical content of this utility model, specific embodiments are provided below in conjunction with the accompanying drawings.

[0028] This utility model proposes a high-temperature resistant, high-heat-dissipation energy storage continuous charge-discharge cable, comprising two or three conductors 10 arranged side by side. It should be understood that the aforementioned charge-discharge cable is a DC connection cable used between battery clusters or between a cluster and an inverter, and its core conductors are mainly 2 to 3.

[0029] Furthermore, the parallel arrangement of two or three wire cores 10 ensures that each wire core 10 has an independent and maximized heat dissipation surface, thus alleviating the problem of heat accumulation inside the multi-core stranded structure.

[0030] Combination Figure 1 and Figure 2 As shown, the inner sheath layer 20 is extruded over the outer wall of the multiple wire cores 10, and the inner sheath layer 20 is constructed to conform to the outer contour formed by the outer contour of the cross-section and the multiple wire cores 10 arranged side by side.

[0031] In this way, the inner sheath layer 20 can evenly wrap multiple cores 10, and a gap can be formed between two cores 10, which is conducive to the outer sheath layer 30 forming a good bonding effect with the inner sheath layer 20 in the subsequent extrusion process.

[0032] Combination Figure 1 and Figure 2As shown, the outer sheath layer 30 is extruded onto the surface of the inner sheath layer 20. The outer sheath layer 30 is constructed to have two arc surfaces and two planes 31. The arc surfaces and the surface of the wire core 10 form a first heat dissipation path, and the planes 31 and the surface of the wire core 10 form a second heat dissipation path.

[0033] Thus, compared to cables with circular cross-sections, the second heat dissipation path can be significantly shortened to achieve better heat dissipation and improve the cable's temperature resistance. In addition, since the battery modules are stacked in a rectangular shape and the electrical connection points are mostly on the same plane, flat cross-section cables are more conducive to installation, saving space, resulting in neat wiring and more uniform stress.

[0034] Furthermore, since the current between battery packs is DC, the skin effect and proximity effect are weak, the requirements for the shape of the conductor are not strict, and the parallel structure will not introduce unacceptable additional inductance.

[0035] Combination Figure 3 and Figure 4 As shown, the wire core 10 includes stranded conductor 11, insulation layer 12, fire-resistant layer 13 and heat-conducting layer 14 distributed from the inside to the outside. The inner sheath layer 20 is extruded on the outer wall of the heat-conducting layer 14. The heat-conducting layer 14 is a composite structure layer composed of a metal heat-conducting layer and a heat-conducting paste layer.

[0036] In an optional embodiment, the stranded conductor 11 comprises a multi-layered, tightly stranded structure of circular copper wires, including silver-plated or nickel-plated copper wires. Silver-plated or nickel-plated copper wires provide superior oxidation and corrosion resistance compared to tin-plated or bare copper, maintaining stable contact resistance and conductivity, and preventing increased heat generation due to conductor surface deterioration.

[0037] In an optional embodiment, the insulating layer 12 includes a silicone rubber insulating layer. The silicone rubber insulating layer has a temperature resistance of 125°C to 150°C, meeting the high temperature resistance requirements.

[0038] Furthermore, the refractory layer 13 includes a mica tape wrapping layer 131 and a glass fiber braided layer 132.

[0039] Thus, the mica tape wrapping layer 131 and the glass fiber braided layer 132 together form a fire-resistant layer that can withstand temperatures exceeding 500°C and is fireproof, providing a high level of thermal protection.

[0040] Combination Figure 3 As shown, the thermal grease layer includes a first thermal grease layer 141 coated on the surface of the refractory layer 13, and the metal thermally conductive layer includes a copper strip covering layer 142 covering the surface of the first thermal grease layer 141. Thus, by filling the gaps in the surface of the glass fiber braided layer 132 with thermal grease, air gaps can be reduced, improving thermal conductivity. The copper strip covering layer 142 on the outer layer further enhances outward thermal conductivity.

[0041] Preferably, the thermal paste layer further includes a second thermal paste layer coated on the surface of the copper strip covering layer 142.

[0042] In this way, a thermally conductive layer with close contact is formed between the copper strip cladding layer 142 and the inner sheath layer 20, reducing the impact of poor thermal conductivity caused by air gaps.

[0043] In an optional embodiment, the inner sheath layer 20 includes an alkali-free ceramicized silicone rubber extrusion layer. The alkali-free ceramicized silicone rubber extrusion layer provides additional temperature and mechanical protection, and the ceramicized silicone rubber ablates into a robust ceramic shell at high temperatures, providing fire resistance and heat insulation.

[0044] Furthermore, the outer sheath layer 30 includes a silicone rubber sheath layer. The silicone rubber sheath layer, with its excellent temperature resistance, achieves high temperature and weather resistance. Meanwhile, the highly thermally conductive modified polyolefin sheath layer, which also contains thermally conductive fillers (such as aluminum nitride), not only exhibits high temperature and weather resistance but also efficiently dissipates internal heat into the ambient air, improving heat dissipation capacity.

[0045] In the above embodiments, combined with Figure 1 and Figure 2 As shown, the surface of plane 31 is provided with heat dissipation groove 32, and the heat dissipation groove 32 and the surface of wire core 10 form a third heat dissipation path. The length of the third heat dissipation path is less than the length of the second heat dissipation path.

[0046] Thus, the heat dissipation capacity of the cable can be further improved by setting up the heat dissipation slot 32.

[0047] Preferably, the heat dissipation groove 32 is located at the point where the two wire cores 10 are tangent. Since the heat dissipation path is longest at the point where the two wire cores 10 are tangent, placing the heat dissipation groove 32 at this location can minimize the length of the heat dissipation path and improve the heat dissipation capacity.

[0048] In conjunction with the above embodiments, this application abandons the circular cable of the prior art and arranges each insulated core with an independent metal heat dissipation layer in parallel, and then extrudes the outer sheath as a whole. This structure allows each core to dissipate heat directly through its own heat dissipation layer and outer sheath, resulting in the shortest heat dissipation path and the highest efficiency. It reduces the heat accumulation inside the twisting and achieves the shortest and most optimized heat dissipation path. At the same time, this structure greatly facilitates the installation in confined spaces. The side-by-side arrangement of the positive and negative cores also makes the wiring operation clear at a glance and effectively reduces the risk of installation errors.

[0049] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Those skilled in the art to which this invention pertains can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of this invention shall be determined by the claims.

Claims

1. A high-temperature resistant, high-heat dissipation energy storage continuous charge-discharge cable, characterized in that, include: Two or three wire cores arranged side by side (10); The inner sheath layer (20) is extruded on the outer wall of the multiple wire cores (10), and the inner sheath layer (20) is constructed to conform to the outer contour formed by the outer contour of the cross section and the multiple wire cores (10) arranged side by side. An outer sheath layer (30) is extruded onto the surface of the inner sheath layer (20). The outer sheath layer (30) is constructed to have two arc surfaces and two planes (31). The arc surfaces and the surface of the wire core (10) form a first heat dissipation path, and the planes (31) and the surface of the wire core (10) form a second heat dissipation path. The core (10) includes stranded conductor (11), insulation layer (12), fire-resistant layer (13) and heat-conducting layer (14) distributed from the inside to the outside. The inner sheath layer (20) is extruded onto the outer wall of the heat-conducting layer (14). The heat-conducting layer (14) is a composite structure layer composed of a metal heat-conducting layer and a heat-conducting paste layer.

2. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The stranded conductor (11) comprises a multi-layer circular copper wire tightly stranded structure, wherein the copper wire comprises silver-plated or nickel-plated copper wire.

3. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The insulating layer (12) includes a silicone rubber insulating layer.

4. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The refractory layer (13) includes a mica tape wrapping layer (131) and a glass fiber braided layer (132).

5. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The thermal conductive paste layer includes a first thermal conductive paste layer (141) coated on the surface of the refractory layer (13), and the metal thermal conductive layer includes a copper strip covering layer (142) covering the surface of the first thermal conductive paste layer (141).

6. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 5, characterized in that, The thermal paste layer also includes a second thermal paste layer coated on the surface of the copper strip covering layer (142).

7. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The inner sheath layer (20) includes an alkali-free ceramicized silicone rubber extrusion layer.

8. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 1, characterized in that, The outer sheath layer (30) includes a silicone rubber sheath layer or a high thermal conductivity modified polyolefin sheath layer.

9. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to any one of claims 1-8, characterized in that, The surface of the plane (31) is provided with a heat dissipation groove (32), and the heat dissipation groove (32) and the surface of the wire core (10) form a third heat dissipation path. The length of the third heat dissipation path is less than the length of the second heat dissipation path.

10. The high-temperature resistant, high-heat dissipation energy storage continuous charge / discharge cable according to claim 9, characterized in that, The heat dissipation groove (32) is located at the point where the two wire cores (10) are tangent.

Images