A liquid-cooled electric vehicle charging cable

Abstract

The utility model discloses a kind of liquid-cooled electric vehicle charging cables, including isolation layer, the inside fixed connection of isolation layer has conductor mechanism, the periphery fixed connection of isolation layer has insulating layer, the periphery fixed connection of insulating layer has liquid cooling mechanism, the periphery fixed connection of liquid cooling mechanism has outer sheath, the utility model can effectively reduce the stress concentration of conductor, improve the bending resistance of conductor, solve the problem that conductor outer diameter is out of limit, conductor tensile property is poor, can be overlapped with light non-woven fabric by isolation layer and adopt the reasonable design of wrapping, while effectively protecting conductor mechanism, avoiding its bending loses protection, control product overall outer diameter, improve the convenience of cable use, prevent the phenomenon that coolant is blocked and not passable due to bending in use process, improve heat conduction efficiency, so that insulating layer is well cooled, and then improve the ampacity of same cross section cable, meet high-power charging demand, and can effectively maintain the stability and roundness of cable overall.

Description

Technical Field

[0001] This utility model relates to the field of charging cable technology, and in particular to a liquid-cooled electric vehicle charging cable. Background Technology

[0002] The global automotive industry is accelerating its transformation towards new energy vehicles. my country has ranked first in the world in terms of production, sales, and ownership of new energy vehicles for many consecutive years. As a result, the demand for special cables for new energy vehicles and charging pile cables has surged. However, traditional charging cables face key bottlenecks. With the increase in vehicle range, car owners have an urgent need for high-power fast charging. However, traditional cables are prone to overheating due to current loss during high-power charging, requiring the charging current to be limited, resulting in slow charging speeds and hindering the further popularization of new energy vehicles. At the same time, traditional cables often suffer from poor conductor tensile strength, insufficient bending resistance, difficulty in balancing insulation layer protection and outer diameter control, inefficient heat dissipation structures that are prone to blockage, and weak environmental resistance of the outer sheath, making them unsuitable for complex usage scenarios. In addition, the outdated technology of traditional cables also hinders the upgrading of the charging industry. The lack of comprehensive technical standards makes it difficult to drive the coordinated development of the industrial chain. New liquid-cooled charging cables are urgently needed to overcome these difficulties.

[0003] Existing devices have poor tensile strength and are prone to breakage, insufficient bending resistance, large interlayer electromagnetic induction interference, and the overlap ratio is prone to being too small or too large. The contact area between the coolant and the insulation layer is small, resulting in low heat dissipation efficiency. Furthermore, coolant blockage occurs when bending, making it difficult to increase the current carrying capacity of cables with the same cross-section. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a liquid-cooled electric vehicle charging cable.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A liquid-cooled electric vehicle charging cable includes an insulating layer, a conductor mechanism fixedly connected inside the insulating layer, and an insulating layer fixedly connected around the insulating layer.

[0007] As a further improvement of this utility model: a liquid cooling mechanism is fixedly connected around the perimeter of the insulating layer, and an outer sheath is fixedly connected around the perimeter of the liquid cooling mechanism.

[0008] As a further embodiment of this invention: the conductor mechanism includes aramid twisted rope and soft round copper wire.

[0009] As a further embodiment of this utility model: the aramid twisted rope is fixedly connected to the inner wall of the isolation layer, and the soft round copper wire is fixedly connected to the inner wall of the aramid twisted rope.

[0010] As a further embodiment of this utility model: the liquid cooling mechanism includes a honeycomb pipe, an outer support wall, and an inner support wall.

[0011] As a further embodiment of this utility model: the inner support wall is fixedly connected to the perimeter of the two insulating layers, and the honeycomb pipe is fixedly connected to the perimeter of the two inner support walls.

[0012] As a further embodiment of this utility model: the outer support wall is fixedly connected to the periphery of the honeycomb pipe, and the outer support wall is fixedly connected to the inner wall of the outer sheath.

[0013] Compared with the prior art, this utility model provides a liquid-cooled electric vehicle charging cable, which has the following advantages:

[0014] 1. This liquid-cooled electric vehicle charging cable achieves efficient transmission of high-power charging current through a conductor structure. The insulating layer allows the conductor structure to move freely within the insulation layer. The insulating layer is made of lightweight non-woven fabric, which is wrapped in an overlapping manner to prevent loss of protection during bending due to insufficient overlap, while also avoiding an overall increase in the outer diameter of the product due to excessive overlap. The liquid cooling mechanism improves heat conduction efficiency, ensuring good cooling of the insulated core and increasing the current carrying capacity of the cable with the same cross-section. The outer sheath serves as a protective component, maintaining the overall stability and roundness of the cable. Thus, by utilizing the reasonable design of the lightweight non-woven fabric overlapping wrapping in the insulating layer, the conductor structure is effectively protected, preventing loss of protection during bending, while controlling the overall outer diameter of the product, improving the ease of use of the cable, and ensuring sufficient cooling of the insulated core, thereby increasing the current carrying capacity of the cable with the same cross-section to meet high-power charging requirements. It also effectively maintains the overall stability and roundness of the cable, enhancing its durability and adaptability.

[0015] 2. This liquid-cooled electric vehicle charging cable uses aramid twisted rope as the carrying core and soft round copper wire layered winding structure for the conductor to maintain the conductor's excellent flexibility. The adjacent layers are in opposite directions, which can effectively reduce the electromagnetic induction between adjacent layers. This can effectively reduce the stress concentration of the conductor and improve the conductor's bending resistance. The aramid twisted rope gives the conductor high tensile strength, solving the problems of conductor outer diameter exceeding the standard and poor conductor tensile performance.

[0016] 3. This liquid-cooled electric vehicle charging cable immerses the entire insulation layer in coolant, ensuring complete contact between the coolant and the insulation surface. The large contact area allows the coolant to flow through the honeycomb channels, significantly reducing the heat generated by the insulated core wires during operation. The honeycomb structure provides stable support, serving as a support layer between the insulation layer and the outer sheath. Combined with the outer and inner support walls, this results in a smooth cable appearance. The mesh structure ensures that the coolant can still flow smoothly when bent, preventing coolant blockage caused by bending during use. This improves heat conduction efficiency, effectively cools the insulation layer, and increases the current carrying capacity of cables with the same cross-section.

[0017] The parts of this device not covered herein are the same as or can be implemented using existing technologies. This utility model has a simple structure and is easy to operate. Attached Figure Description

[0018] Figure 1 This is a front view of a liquid-cooled electric vehicle charging cable proposed in this utility model;

[0019] Figure 2 This is a front view of a liquid-cooled electric vehicle charging cable proposed in this utility model;

[0020] Figure 3 This is a detailed internal view of a liquid-cooled electric vehicle charging cable proposed in this utility model.

[0021] Figure 4 A cross-sectional view of the conductor structure of a liquid-cooled electric vehicle charging cable proposed in this utility model;

[0022] Figure 5 Detailed diagram of the liquid cooling mechanism of a liquid-cooled electric vehicle charging cable proposed in this utility model.

[0023] In the diagram: 1. Conductor mechanism; 2. Insulation layer; 3. Insulation layer; 4. Liquid cooling mechanism; 5. Outer sheath; 101. Aramid twisted rope; 102. Soft round copper wire; 401. Honeycomb pipe; 402. Outer support wall; 403. Inner support wall. Detailed Implementation

[0024] 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.

[0025] In the description of this utility model, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, 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.

[0026] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0027] A liquid-cooled electric vehicle charging cable, such as Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, it includes an isolation layer 2, a conductor mechanism 1 is fixedly connected inside the isolation layer 2, an insulation layer 3 is fixedly connected around the isolation layer 2, a liquid cooling mechanism 4 is fixedly connected around the insulation layer 3, and an outer sheath 5 is fixedly connected around the liquid cooling mechanism 4.

[0028] During operation, high-power charging current is effectively transmitted through conductor mechanism 1. Insulation layer 2 allows conductor mechanism 1 to move freely within insulation layer 3. Insulation layer 2 is made of lightweight non-woven fabric, which is wrapped in an overlapping manner to prevent loss of protection when bending due to insufficient overlap. It also avoids an overall increase in the outer diameter of the product due to excessive overlap. Liquid cooling mechanism 4 improves heat conduction efficiency, ensuring good cooling of the insulated core and increasing the current carrying capacity of cables with the same cross-section. Outer sheath 5 serves as a protective component, maintaining the overall stability and roundness of the cable. Thus, by utilizing the reasonable design of overlapping wrapping of lightweight non-woven fabric in insulation layer 2, conductor mechanism 1 is effectively protected, preventing loss of protection when bending, while controlling the overall outer diameter of the product, improving the ease of use of the cable, and ensuring sufficient cooling of the insulated core, thereby increasing the current carrying capacity of cables with the same cross-section, meeting the high-power charging requirements, and effectively maintaining the overall stability and roundness of the cable, enhancing the cable's durability and adaptability.

[0029] To achieve efficient transmission of high-power charging current, such as Figure 4As shown, the conductor mechanism 1 includes an aramid twisted rope 101 and a soft round copper wire 102, with the aramid twisted rope 101 fixedly connected to the inner wall of the isolation layer 2 and the soft round copper wire 102 fixedly connected to the inner wall of the aramid twisted rope 101.

[0030] During operation, the aramid twisted rope 101 serves as the load-bearing core, and the conductor uses a layered winding structure of soft round copper wire 102 to maintain the conductor's excellent flexibility. The adjacent layers are wound in opposite directions, which can effectively reduce the electromagnetic induction between adjacent layers. As a result, the stress concentration of the conductor can be effectively reduced, and the conductor's bending resistance can be improved. The aramid twisted rope 101 gives the conductor high tensile strength, solving the problems of conductor outer diameter exceeding the standard and conductor's poor tensile performance.

[0031] To efficiently dissipate heat from the cable and support high-power charging, such as Figure 5 As shown, the liquid cooling mechanism 4 includes a honeycomb pipe 401, an outer support wall 402, and an inner support wall 403. The inner support wall 403 is fixedly connected to the periphery of the two insulating layers 3. The honeycomb pipe 401 is fixedly connected to the periphery of the two inner support walls 403. The outer support wall 402 is fixedly connected to the periphery of the honeycomb pipe 401 and is fixedly connected to the inner wall of the outer sheath 5.

[0032] During operation, the insulation layer 3 is completely immersed in the coolant, ensuring full contact between the coolant and the insulation surface. The large contact area allows the coolant to flow through the honeycomb pipes 401, significantly reducing the heat generated by the insulated core wires. The honeycomb structure of the pipes 401 provides stable support, serving as a support layer between the insulation layer 3 and the outer sheath 5. Together with the outer support wall 402 and the inner support wall 403, it ensures a rounded cable appearance. The mesh structure allows the coolant to continue flowing smoothly even when bent, preventing coolant blockage caused by bending during use. This improves heat transfer efficiency, effectively cools the insulation layer 3, and increases the current carrying capacity of cables with the same cross-section.

[0033] Working principle: The aramid twisted rope 101 serves as the carrying core, and the conductor adopts a layered winding structure of soft round copper wire 102 to maintain the conductor's excellent flexibility. The adjacent layers are in opposite directions, which can effectively reduce the electromagnetic induction between adjacent layers.

[0034] The isolation layer 2 allows the conductor mechanism 1 to move freely inside the insulation layer 3. The isolation layer 2 is made of lightweight non-woven fabric. The lightweight non-woven fabric is wrapped in an overlapping manner to prevent loss of protection when bending due to insufficient overlap. At the same time, it can also avoid the overall increase in the outer diameter of the product due to excessive overlap.

[0035] The insulation layer 3 is completely immersed in the coolant, and the coolant is in complete contact with the insulation surface with a large contact area. The coolant flows through the honeycomb pipe 401, which greatly removes the heat generated by the insulated core wire during operation. The honeycomb structure of the honeycomb pipe 401 provides stable support and serves as a support layer between the insulation layer 3 and the outer sheath 5. Together with the outer support wall 402 and the inner support wall 403, it makes the cable look round. When bent, the mesh structure can ensure that the coolant can still pass smoothly. The outer sheath 5 serves as a protective component, maintaining the overall stability and roundness of the cable.

[0036] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A liquid-cooled electric vehicle charging cable, comprising an insulating layer (2), characterized in that, The isolation layer (2) is fixedly connected to a conductor mechanism (1), and the isolation layer (2) is fixedly connected to an insulating layer (3) around its perimeter. The insulating layer (3) is fixedly connected to a liquid cooling mechanism (4) around its perimeter, and an outer sheath (5) is fixedly connected to the perimeter of the liquid cooling mechanism (4). The conductor mechanism (1) includes an aramid twisted rope (101) and a soft round copper wire (102). The aramid twisted rope (101) is fixedly connected to the inner wall of the isolation layer (2), and the soft round copper wire (102) is fixedly connected to the inner wall of the aramid twisted rope (101). The liquid cooling mechanism (4) includes a honeycomb pipe (401), an outer support wall (402) and an inner support wall (403). The inner support wall (403) is fixedly connected to the periphery of the two insulating layers (3). The honeycomb pipe (401) is fixedly connected to the periphery of the two inner support walls (403). The outer support wall (402) is fixedly connected to the periphery of the honeycomb pipe (401) and is fixedly connected to the inner wall of the outer sheath (5).

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