A flexible high-power charging cable for new energy vehicles

Abstract

The utility model provides a flexible high -power charging cable for new energy vehicle, its through reasonable design power line core, control line core and the arrangement of auxiliary line core, and the symmetrical setting of ground wire core and filling fiber core makes the cable internal line core whole circle arrangement. The flexible layer contains a plurality of sector ring elastomer of annular setting, and sets up carbon fiber core at the elastomer gap, not only promotes the cable flexibility and internal structure support, enhances the voltage resistance of cable, the carbon fiber core of setting in the middle is favorable to the transmission of heat. The outside of flexible layer is sequentially provided with wrapping tape layer, flame -retardant layer, copper foil layer, heat conducting layer and wear -resisting outer sheath, realizes the multiple function of flame -retardant, shielding, heat dissipation and wear -resisting, wherein the wear -resisting outer sheath adopts annular groove structure, can promote wear resistance, increase the heat dissipation area. Therefore, the utility model discloses a flexible high -power charging cable for new energy vehicle has high flexibility, excellent flame -retardant, good heat dissipation performance, voltage resistance and bending resistance.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically a flexible high-power charging cable for new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, vehicles are increasingly reliant on charging systems in daily use. To shorten charging time and improve efficiency, high-power charging methods are gradually becoming mainstream. In this process, charging cables, as crucial components for power transmission, directly impact the stability and reliability of new energy vehicle charging systems due to their safety, flexibility, and durability.

[0003] Existing charging cables for new energy vehicles typically use multi-strand copper wires as conductors, covered with an insulation layer and sheath. However, some traditional charging cables for new energy vehicles have shortcomings in terms of flexibility, flame retardancy, and signal transmission stability. Therefore, how to improve the flexibility, heat dissipation, and flame retardancy of cables is a problem that is constantly being addressed in this field. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a flexible high-power charging cable for new energy vehicles, which solves the problems that some existing new energy vehicle charging cables need further improvement in terms of flexibility, heat dissipation performance, and flame retardant performance.

[0005] A flexible high-power charging cable for new energy vehicles includes two power cores, two control cores, two auxiliary cores, one grounding core, one filler fiber core, a flame-retardant filling layer, a flexible layer, a wrapping tape layer, a flame-retardant layer, a copper foil layer, a thermally conductive layer, and a wear-resistant outer sheath. The power cores, control cores, and auxiliary cores are sequentially attached in pairs. The grounding core and the filler fiber core are symmetrically arranged in the gaps between the power cores, control cores, and auxiliary cores. The flexible layer includes a plurality of annularly arranged fan-shaped elastic bodies with gaps between adjacent fan-shaped elastic bodies, and a carbon fiber core is disposed in the gaps. The outer side of the flexible layer is sequentially arranged from the inside to the outside as the wrapping tape layer, the flame-retardant layer, the copper foil layer, the thermally conductive layer, and the wear-resistant outer sheath. The wear-resistant outer sheath has a plurality of annularly recessed grooves from the outside to the inside. The flame-retardant filling layer is filled within the flexible layer.

[0006] Preferably, the power core is made of multiple strands of silver-plated copper wire twisted together and is covered with a polyolefin insulation layer.

[0007] Preferably, the control wire core comprises a conductor formed by twisting together several tinned copper wires, the conductor is covered with a low-smoke halogen-free flame-retardant insulation layer, and a shielding braided layer is arranged around the outside of the low-smoke halogen-free flame-retardant insulation layer.

[0008] Preferably, the auxiliary wire core is made of several strands of tin-plated copper wires twisted together and is covered with a polyurethane insulation layer.

[0009] Preferably, the grounding core is made of several bare copper wires twisted together and is covered with a green insulating marking layer.

[0010] Preferably, the filling fiber core is an aramid fiber core.

[0011] Preferably, the flame-retardant filler layer is a magnesium hydroxide flame-retardant filler layer or an aluminum hydroxide flame-retardant filler layer doped with alumina particles.

[0012] Preferably, the sector-shaped elastomer is a silicone rubber sector-shaped elastomer.

[0013] Preferably, the wrapping tape layer is a polyester nonwoven fabric wrapping tape layer or a polyester film wrapping tape layer.

[0014] Preferably, the flame retardant layer is a low-smoke halogen-free flame-retardant polyolefin flame retardant layer or a fluororubber flame retardant layer.

[0015] Preferably, the thermally conductive layer is a thermally conductive silicone layer.

[0016] Preferably, the wear-resistant outer sleeve is a thermoplastic polyurethane wear-resistant outer sleeve doped with thermally conductive particles or a silicone rubber wear-resistant outer sleeve doped with thermally conductive particles.

[0017] Compared with the prior art, the present invention has the following beneficial effects: This utility model provides a flexible high-power charging cable for new energy vehicles, comprising two power cores, two control cores, two auxiliary cores, one grounding core, one filler fiber core, a flame-retardant filling layer, a flexible layer, a wrapping tape layer, a flame-retardant layer, a copper foil layer, a thermally conductive layer, and a wear-resistant outer sheath. By rationally arranging the power, control, and auxiliary cores, and symmetrically positioning the grounding core and filler fiber core, the internal cores are arranged in a circular pattern with uniform stress, thereby improving the overall flexibility of the cable. The flexible layer includes multiple annularly arranged sector-shaped elastomers, with carbon fiber cores placed between the elastomers. This not only enhances the cable's flexibility and internal structural support, and strengthens its pressure resistance, but also facilitates heat transfer. The flexible layer is further surrounded by a wrapping tape layer, a flame-retardant layer, a copper foil layer, a thermally conductive layer, and a wear-resistant outer sheath, achieving multiple functions including flame retardancy, shielding, heat dissipation, and wear resistance. Therefore, the flexible high-power charging cable for new energy vehicles of this utility model has high flexibility, excellent flame retardancy, good heat dissipation performance, pressure resistance and bending resistance, which can meet the high requirements for cable safety, durability and reliability during the high-power charging process of new energy vehicles and improve the service life of the cable. Attached Figure Description

[0018] Figure 1 This is a structural schematic diagram of the flexible high-power charging cable for new energy vehicles described in this utility model.

[0019] in: 10-Power core, 20-Control core, 30-Auxiliary core, 40-Grounding core, 50-Fiber filling core, 60-Flame-retardant filling layer, 70-Flexible layer, 80-Wrapping tape layer, 90-Flame-retardant layer, 11-Copper foil layer, 12-Heat-conducting layer, 13-Wear-resistant outer sheath, 71-Fan-ring elastomer, 72-Gap, 73-Carbon fiber core, 74-Groove. Detailed Implementation

[0020] The embodiments described below are merely some embodiments of this utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0021] See Figure 1This embodiment provides a flexible high-power charging cable for new energy vehicles, comprising two power cores 10, two control cores 20, two auxiliary cores 30, one grounding core 40, one filler fiber core 50, a flame-retardant filling layer 60, a flexible layer 70, a wrapping tape layer 80, a flame-retardant layer 90, a copper foil layer 11, a thermally conductive layer 12, and a wear-resistant outer sheath 13. The power cores 10, control cores 20, and auxiliary cores 30 are sequentially attached in pairs. The grounding core 40 and the filler fiber core 50 are symmetrically arranged on the power cores 10 and 20. The gap between the control core 20 and the auxiliary core 30 is specified. The flexible layer 70 includes a plurality of annularly arranged fan-shaped elastic bodies 71. A gap 72 is provided between two adjacent fan-shaped elastic bodies 71, and a carbon fiber core 73 is provided at the gap 72. The flexible layer 70 is provided with the wrapping tape layer 80, the flame retardant layer 90, the copper foil layer 11, the thermally conductive layer 12, and the wear-resistant outer sheath 13 in sequence from the inside to the outside. The wear-resistant outer sheath 13 is provided with a plurality of annularly recessed grooves 74 from the outside to the inside. The flame retardant filling layer 60 is filled in the flexible layer 70.

[0022] Preferably, the power core 10 is made of multiple strands of silver-plated copper wire twisted together and covered with a polyolefin insulation layer. The twisted structure of the multiple strands of silver-plated copper wire improves the flexibility and fatigue resistance of the conductor, enabling the cable to remain stable during bending, coiling, and long-term use; the polyolefin insulation layer provides good electrical insulation performance and mechanical protection, improving the cable's heat resistance and safety.

[0023] Preferably, the control core 20 comprises a conductor formed by stranding several tinned copper wires, the conductor being covered with a low-smoke halogen-free flame-retardant insulation layer, and a shielding braided layer surrounding the outer side of the low-smoke halogen-free flame-retardant insulation layer. The tinned copper wire stranded conductor improves the flexibility and conductivity stability of the control core 20, while the low-smoke halogen-free flame-retardant insulation layer reduces the release of smoke and harmful gases in the event of overheating or fire, improving cable safety; the shielding braided layer effectively prevents electromagnetic interference, ensuring stable and reliable signal transmission. It should be noted that the shielding braided layer is a braided mesh structure formed by interlacing multiple strands of tinned copper wire. This structure provides good electromagnetic shielding, effectively preventing external electromagnetic interference from affecting the control signal, while also being flexible, ensuring that the overall flexibility and reliability of the cable are not affected when the control core 20 is bent or wound.

[0024] Preferably, the auxiliary conductor 30 is composed of several strands of tinned copper wires twisted together and covered with a polyurethane insulation layer. The tinned copper wire stranded structure enhances the flexibility and fatigue resistance of the auxiliary conductor 30, allowing it to withstand repeated bending of the cable; the polyurethane insulation layer has good wear resistance and mechanical protection, effectively preventing damage to the conductor from external friction or wear, and improving the cable's durability and reliability.

[0025] Preferably, the grounding core 40 is composed of several bare copper wires twisted together and covered with a green insulating marking layer. This grounding core 40 has good conductivity and flexibility, effectively carrying the leakage current or static electricity generated during cable operation, ensuring the safety of the entire cable; the green insulating marking layer not only facilitates identification of the grounding wire location and avoids wiring errors, but also enhances insulation protection, further improving the safety of cable use.

[0026] Preferably, the filling fiber core 50 is an aramid fiber core. Aramid fibers have high strength, high temperature resistance, and good wear resistance. When placed inside the cable, they can fill the gaps 72 between the wire cores, keeping the wire cores inside the cable arranged in a round shape and with uniform stress, thereby improving the overall flexibility and mechanical stability of the cable, and also increasing the tensile strength of the cable. At the same time, the high temperature resistance of the aramid fiber core helps to improve the safety and service life of the cable under high power charging conditions.

[0027] Preferably, the flame-retardant filler layer 60 is a magnesium hydroxide flame-retardant filler layer 60 or an aluminum hydroxide flame-retardant filler layer 60 doped with alumina particles. This flame-retardant filler layer 60 not only possesses excellent flame-retardant properties, effectively preventing flame spread under high temperature or fire conditions and improving cable safety; simultaneously, the doped alumina particles improve thermal conductivity, facilitating the dissipation of heat from the cable's interior to the exterior, thereby enhancing the overall heat dissipation performance and reliability of the cable during high-power charging. More preferably, the flame-retardant filler layer 60 is a magnesium hydroxide flame-retardant filler layer 60 doped with alumina particles.

[0028] Preferably, the fan-shaped elastomer 71 is a silicone rubber fan-shaped elastomer 71, and a gap 72 is provided between two adjacent silicone rubber fan-shaped elastomers 71, and a carbon fiber core 73 is provided at the gap 72. By leaving a gap 72 between adjacent silicone rubber fan-shaped elastomers 71, each fan ring can deform independently when the cable is bent or compressed, avoiding stress concentration, thereby improving the flexibility and fatigue resistance of the cable. The carbon fiber core 73 embedded in the gap 72 not only plays a structural support role and further enhances the pressure resistance of the cable, but also the excellent thermal conductivity of carbon fiber can accelerate the conduction and dissipation of heat inside the cable, improve the heat dissipation effect, and ensure the safe and stable operation of the cable.

[0029] Preferably, the wrapping tape layer 80 is a polyester nonwoven fabric wrapping tape layer 80 or a polyester film wrapping tape layer 80. The wrapping tape layer 80 is circularly wrapped around the outer side of the inner layer structure of the cable, used to tightly bind the internal cores and fillers, making the cable as a whole round, preventing the internal structure from becoming loose or deformed, and improving the stability of the cable structure. The thickness of the wrapping tape layer 80 is preferably 0.05~0.3mm, more preferably 0.1mm.

[0030] Preferably, the flame-retardant layer 90 is a low-smoke halogen-free flame-retardant polyolefin flame-retardant layer 90 or a fluororubber flame-retardant layer 90. The flame-retardant layer 90 of this application can significantly improve the overall flame-retardant rating and environmental adaptability of the cable, thereby ensuring the safety of the cable during high-power charging of new energy vehicles. It should be noted that the low-smoke halogen-free flame-retardant polyolefin flame-retardant layer 90 or the fluororubber flame-retardant layer 90 is doped with alumina or boron nitride during preparation. The thickness of the flame-retardant layer 90 in this application is 0.2–1.5 mm, preferably 0.5 mm.

[0031] Preferably, the thermally conductive layer 12 is a thermally conductive silicone layer. The thermally conductive silicone layer has excellent thermal conductivity, enabling it to quickly conduct the heat generated during operation by the power core 10, control core 20, and auxiliary core 30 inside the cable to the outer wear-resistant outer sheath 13. The wear-resistant outer sheath 13 then exchanges heat with the air, effectively reducing internal temperature rise, preventing overheating, and improving the safety and reliability of the cable under high-power charging conditions. Simultaneously, the thermally conductive silicone itself is flexible, allowing it to work synergistically with the flexible layer 70 and the wear-resistant outer sheath 13 without affecting the overall flexibility and bending resistance of the cable, thus balancing heat dissipation efficiency and mechanical properties. It should also be noted that the copper foil layer 11 is disposed within the thermally conductive layer 12. The copper foil layer 11 serves two purposes: firstly, it provides shielding, effectively preventing external electromagnetic interference from affecting the signal transmission of the control core 20, thus ensuring the stability and reliability of signal transmission; secondly, the copper foil layer 11 has high thermal conductivity and can act as a heat conduction channel, transferring some of the heat generated by the internal core to the thermally conductive silicone layer and the outer wear-resistant outer sheath 13, thereby synergistically achieving the heat dissipation function of the cable, further reducing the internal temperature rise of the cable, and improving the safety and durability of the cable during high-power charging.

[0032] Preferably, the wear-resistant outer sheath 13 is a thermoplastic polyurethane wear-resistant outer sheath 13 doped with thermally conductive particles or a silicone rubber wear-resistant outer sheath 13 doped with thermally conductive particles. The wear-resistant outer sheath 13 doped with thermally conductive particles not only improves the material's wear resistance and mechanical protection capabilities, but also rapidly conducts heat generated inside the cable to the outer surface by increasing the material's thermal conductivity. Combined with the annular groove 74 structure on the outer sheath surface, it increases the heat dissipation area and promotes air convection, thereby effectively reducing the cable surface temperature and improving heat dissipation efficiency. It should be noted that the thermally conductive particles are highly thermally conductive inorganic particles such as alumina particles, boron nitride particles, graphite, or graphene particles. These particles are dispersed in the wear-resistant outer sheath 13 material, which improves the overall thermal conductivity of the material without significantly affecting its flexibility and wear resistance, thus effectively enhancing the cable's heat conduction and dissipation capabilities while maintaining its mechanical protection function. Of course, the wear-resistant outer sheath 13 can also be a common thermoplastic polyurethane wear-resistant outer sheath 13 or a silicone rubber wear-resistant outer sheath 13. The wear-resistant outer sheath 13 has a sufficient heat exchange area with the outside air, which enables the cable to exchange heat and thus dissipate heat to a certain extent.

[0033] This utility model provides a flexible high-power charging cable for new energy vehicles, comprising two power cores 10, two control cores 20, two auxiliary cores 30, one grounding core 40, one filler fiber core 50, a flame-retardant filling layer 60, a flexible layer 70, a wrapping tape layer 80, a flame-retardant layer 90, a copper foil layer 11, a thermally conductive layer 12, and a wear-resistant outer sheath 13. By rationally arranging the power cores 10, control cores 20, and auxiliary cores 30, and symmetrically arranging the grounding core 40 and filler fiber core 50, the internal cores of the cable are arranged in a circular pattern with uniform stress, thereby improving the overall flexibility of the cable. The flexible layer 70 includes multiple annularly arranged sector-shaped elastic bodies 71, with carbon fiber cores 73 placed at the gaps 72 between the elastic bodies. This not only improves the cable's flexibility and internal structural support, and enhances its pressure resistance, but the carbon fiber cores 73 in the middle also facilitate heat transfer. The flexible layer 70 is sequentially surrounded by a wrapping tape layer 80, a flame-retardant layer 90, a copper foil layer 11, a thermally conductive layer 12, and a wear-resistant outer sheath 13, achieving multiple functions of flame retardancy, shielding, heat dissipation, and wear resistance. The wear-resistant outer sheath 13 employs an annular groove structure 74, which enhances wear resistance, increases heat dissipation area, strengthens the cable's bending resistance, and improves heat release efficiency. Therefore, this new type of flexible high-power charging cable for new energy vehicles combines high flexibility, excellent flame retardancy, good heat dissipation performance, pressure resistance, and bending resistance, meeting the high requirements for cable safety, durability, and reliability during high-power charging of new energy vehicles and extending cable lifespan.

[0034] The above-disclosed embodiments are merely some preferred embodiments of the present utility model, and should not be construed as limiting the scope of the present utility model. Therefore, any equivalent changes made in accordance with the scope of the present utility model patent application shall still fall within the scope of the present utility model.

Claims

1. A flexible high-power charging cable for new energy vehicles, characterized in that: It comprises two power cores, two control cores, two auxiliary cores, one grounding core, one filler fiber core, a flame-retardant filler layer, a flexible layer, a wrapping tape layer, a flame-retardant layer, a copper foil layer, a thermally conductive layer, and a wear-resistant outer sheath. The power cores, control cores, and auxiliary cores are sequentially attached in pairs. The grounding core and the filler fiber core are symmetrically arranged in the gaps between the power cores, control cores, and auxiliary cores. The flexible layer comprises a plurality of annularly arranged fan-shaped elastomers, with gaps between adjacent fan-shaped elastomers and carbon fiber cores. The outer side of the flexible layer is sequentially arranged from the inside to the outside as the wrapping tape layer, flame-retardant layer, copper foil layer, thermally conductive layer, and wear-resistant outer sheath. The wear-resistant outer sheath has a plurality of annularly recessed grooves from the outside to the inside. The flame-retardant filler layer is filled within the flexible layer.

2. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The power core is made of multiple strands of silver-plated copper wire twisted together and covered with a polyolefin insulation layer.

3. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The control conductor comprises a conductor formed by twisting together several tinned copper wires. The conductor is covered with a low-smoke halogen-free flame-retardant insulation layer, and a shielding braid is arranged around the outside of the low-smoke halogen-free flame-retardant insulation layer.

4. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The auxiliary conductor is made of several strands of tinned copper wires twisted together and covered with a polyurethane insulation layer.

5. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The grounding core is made of several bare copper wires twisted together and covered with a green insulating marking layer.

6. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The filling fiber core is an aramid fiber core.

7. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The flame-retardant filler layer is a magnesium hydroxide flame-retardant filler layer or an aluminum hydroxide flame-retardant filler layer doped with alumina particles.

8. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The sector-shaped elastomer is a silicone rubber sector-shaped elastomer.

9. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The thermally conductive layer is a thermally conductive silicone layer.

10. The flexible high-power charging cable for new energy vehicles as described in claim 1, characterized in that, The wear-resistant outer sleeve is a thermoplastic polyurethane wear-resistant outer sleeve doped with thermally conductive particles or a silicone rubber wear-resistant outer sleeve doped with thermally conductive particles.

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