Multi-core liquid-cooled charging cable structure

Abstract

The utility model relates to liquid cooling charging cable technical field especially is a kind of multicore liquid cooling charging cable structure, including cable body and the end head of being set to the both ends of cable body, cable body includes outer sheath, the inside of outer sheath is equipped with inner sheath, the inner chamber of inner sheath is equipped with multiple cable core and heat-conducting silica gel pipe, multiple support assemblies are equipped between cable core and heat-conducting silica gel pipe, multiple support assemblies are equidistantly spaced arrangement, support assembly includes support frame, the center of support frame is penetrated and is equipped with the through-hole for accommodating heat-conducting silica gel pipe, the outside of support frame is equipped with multiple connecting branch plates, the end of multiple connecting branch plates away from support frame is equipped with the supporting arc plate for supporting heat-conducting silica gel pipe, in the utility model, support assembly can provide accurate positioning and structure support for heat-conducting silica gel pipe, and when cable body dynamic adjustment scene or extrusion by outside, make heat-conducting silica gel pipe keep self form stable, ensure pipe inner flow area and cooling liquid flow rate, to guarantee liquid cooling effect.

Description

Technical Field

[0001] This utility model relates to the field of liquid-cooled charging cable technology, specifically a multi-core liquid-cooled charging cable structure. Background Technology

[0002] Liquid-cooled charging cables are a new technology used in high-power DC fast charging systems. They are mainly used to solve the problem of a large amount of heat generated during high-current charging. The basic principle is to set up a special circulation channel between the cable and the charging gun, add coolant to the channel, and use a power pump to circulate the liquid to remove the heat generated during charging, thereby achieving heat dissipation. In practical applications, liquid-cooled charging cables are widely used in public fast charging stations, highway service area charging stations, and centralized charging scenarios for buses, logistics vehicles, and other operating vehicles. They are an important technical support for promoting the popularization of electric vehicles and improving the charging experience. Traditional cables are mostly supported by rigid frames or simple elastic sheets, lacking precise positioning constraints for liquid cooling tubes and cable cores. When the cable is dynamically adjusted or subjected to external pressure, the liquid cooling tubes may shift or even bend locally as the cable bends. The liquid cooling tubes undergo irregular deformation under direct pressure, resulting in a significant reduction in the flow area inside the tubes. This causes a sharp drop in the flow rate of the coolant inside the tubes, creating "heat dissipation dead zones." Heat from the cable cores cannot be effectively transferred, and the temperature will trigger overheat protection within a short time, interrupting charging. This seriously affects the liquid cooling function and the overall reliability of the cable. Therefore, a multi-core liquid-cooled charging cable structure is proposed to address the above problems. Utility Model Content

[0003] The purpose of this invention is to provide a multi-core liquid-cooled charging cable structure to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A multi-core liquid-cooled charging cable structure includes a cable body and end caps at both ends of the cable body. The cable body includes an outer sheath, and an inner sheath is provided inside the outer sheath. The inner cavity of the inner sheath contains multiple cable cores and thermally conductive silicone tubes. Multiple support components are provided between the cable cores and the thermally conductive silicone tubes. The multiple support components are arranged at equal intervals. Each support component includes a support frame. A through hole for accommodating the thermally conductive silicone tube is opened through the center of the support frame. Multiple connecting plates are provided on the outer side of the support frame. Each of the multiple connecting plates has a supporting arc plate for supporting the thermally conductive silicone tube at its end away from the support frame. Cable grooves for accommodating cable cores are provided between adjacent supporting arc plates. The inner cavity of the connecting plate has a reset structure. One thermally conductive silicone tube passes through the through hole, and the other multiple thermally conductive silicone tubes are located at the supporting arc plates. Multiple cable cores are respectively passed through multiple cable grooves, and the ends of the supporting arc plates are locked on the outside of the cable cores.

[0005] As a further optimization of this utility model, the inner sheath is configured as a composite structure, comprising, from the outside to the inside, a non-woven fabric layer, a nylon filament braided layer, and a single-sided aluminum foil layer, which are bonded together.

[0006] As a further optimization of this utility model, the inner wall of the thermally conductive silicone tube is fixedly connected with a guide rib, the length of the guide rib is the same as the length of the thermally conductive silicone tube, and the guide rib is spirally arranged.

[0007] As a further optimization of this utility model, the multiple connecting support plates, supporting arc plates and cable grooves are arranged in a circular array, and the multiple thermally conductive silicone tubes and cable cores are also arranged in a circular array.

[0008] As a further optimization of this utility model, the reset structure includes reset cavities symmetrically opened in the inner cavities of each connecting support plate. The inner cavity of each reset cavity is provided with a reset spring, and the two ends of the reset spring are respectively fixedly connected to the inner end face of the reset cavity.

[0009] As a further optimization of this utility model, the inner cavity of the reset spring is symmetrically provided with reset support plates, and the ends of the two reset support plates that are far apart from each other are fixedly connected to the inner end face of the reset cavity.

[0010] As a further optimization of this utility model, the two reset support plates are each fixedly connected to a magnetic block at one end that is close to each other, a gap is left between the two magnetic blocks, and the two magnetic blocks are set with the same magnetic pole.

[0011] Compared with the prior art, the beneficial effects of this utility model are: In this invention, the support components can provide precise positioning and structural support for the cable core and the thermally conductive silicone tube, ensuring the performance of the cable core and the thermally conductive silicone tube under normal conditions. The reset structure can maintain the preset structure when the cable body is dynamically adjusted or subjected to external pressure, so that the thermally conductive silicone tube maintains its own shape stability, thereby reducing the deformation of the thermally conductive silicone tube and ensuring the flow area and coolant flow rate inside the tube to ensure the liquid cooling effect. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is an exploded view of the structure of this utility model; Figure 3 This is a schematic diagram of the cable body of this utility model; Figure 4 This utility model Figure 2 Enlarged view of point A; Figure 5This utility model Figure 3 Enlarged view of point B; Figure 6 This is an exploded view of the present invention; Figure 7 This is a schematic diagram of the structure of the inner sheath of this utility model; Figure 8 This is a cross-sectional view of the thermally conductive silicone tube of this utility model; Figure 9 This utility model Figure 8 Enlarged view of point C; Figure 10 This is a schematic diagram of the structure of the cable core of this utility model; Figure 11 This utility model Figure 10 A partial schematic diagram; Figure 12 This is a schematic diagram of the resetting structure of this utility model; Figure 13 A cross-sectional view of the resetting structure of this utility model. Figure 1 ; Figure 14 A cross-sectional view of the resetting structure of this utility model. Figure 2 ; Figure 15 This utility model Figure 14 Enlarged view of point D.

[0013] In the diagram: 1. Cable body; 11. Outer sheath; 12. Inner sheath; 121. Non-woven fabric layer; 122. Nylon braided layer; 123. Single-sided aluminum foil layer; 13. Cable core; 14. Thermally conductive silicone tube; 141. Guide rib; 15. Support assembly; 151. Support frame; 152. Through hole; 153. Connecting support plate; 154. Supporting arc plate; 155. Cable groove; 156. Reset structure; 1561. Reset cavity; 1562. Reset spring; 1563. Reset support plate; 1564. Magnetic block; 2. End. Detailed Implementation

[0014] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0015] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0016] Please see Figures 1-15 This utility model provides a technical solution: A multi-core liquid-cooled charging cable structure includes a cable body 1 and end caps 2 disposed at both ends of the cable body 1. The cable body 1 includes an outer sheath 11, and an inner sheath 12 is provided inside the outer sheath 11. The inner cavity of the inner sheath 12 is provided with multiple cable cores 13 and thermally conductive silicone tubes 14. Multiple support components 15 are provided between the cable cores 13 and the thermally conductive silicone tubes 14. The multiple support components 15 are arranged at equal intervals. Each support component 15 includes a support frame 151. A through hole 152 for accommodating the thermally conductive silicone tubes 14 is opened through the center of the support frame 151. The outer side of the support frame 151 is provided with... There are multiple connecting support plates 153. Each of the multiple connecting support plates 153 has a supporting arc plate 154 for supporting the heat-conducting silicone tube 14 at one end away from the support frame 151. There is a cable groove 155 for accommodating the cable core 13 between adjacent supporting arc plates 154. The inner cavity of the connecting support plate 153 is provided with a reset structure 156. One heat-conducting silicone tube 14 is inserted into the through hole 152. The other multiple heat-conducting silicone tubes 14 are located at the supporting arc plate 154. Multiple cable cores 13 are respectively inserted into multiple cable grooves 155, and the end of the supporting arc plate 154 is locked on the outside of the cable core 13.

[0017] It should be noted that: the cable body 1 and the end 2 constitute a complete charging transmission unit. The end 2 is adapted to the high current transmission of fast charging equipment to ensure the reliability of the connection between the two ends; the outer sheath 11 is made of weather-resistant TPU material, which has tear resistance and oil corrosion resistance, and can resist environmental damage in outdoor charging scenarios. The inner sheath 12 serves as a secondary protection and shielding layer, providing a stable space for the internal cable core 13 and the thermally conductive silicone tube 14. Furthermore, the layout of multiple cable cores 13 and thermally conductive silicone tubes 14 primarily addresses the "high heat generation - insufficient heat dissipation" problem during fast charging. Cable cores 13 are prone to Joule heating when transmitting high currents. The coolant flowing within the thermally conductive silicone tubes 14 can quickly absorb heat and remove it through circulation, keeping the temperature of the cable cores 13 at a low level. The support assembly 15, acting as the "internal skeleton," ensures dimensional stability throughout the entire cable length through its equidistant layout. The equidistant arrangement of the support assembly 15 is crucial: the central through-hole 152 of the support frame 151 fixes the central thermally conductive silicone tube 14, while the outer side connects to the support plate. The cable core 13 and the supporting arc plate 154 form a "radial support structure". The cable groove 155 positions the cable core 13 (avoiding current imbalance caused by core wire twisting) and the end of the supporting arc plate 154 is locked to the outside of the cable core 13 to ensure the relative position stability of the cable core 13 and the thermal conductive silicone tube 14, thus ensuring heat dissipation efficiency. The reset structure 156 is designed for cable bending scenarios. It restores the shape of the support component 15 through the synergy of elasticity and magnetism, avoiding the displacement of the core wire or liquid cooling tube caused by the deformation of the support structure after bending. The whole structure is built into an integrated architecture of "protection-transmission-heat dissipation-deformation resistance". As a further implementation of this solution, the inner sheath 12 is a composite structure. The inner sheath 12 includes, from the outside to the inside, a non-woven fabric layer 121, a nylon filament braided layer 122 and a single-sided aluminum foil layer 123, which are bonded to each other. It should be noted that the "multi-layered functional design" of the inner sheath 12 creates a triple value of "secondary protection - electromagnetic shielding - structural stability". The non-woven fabric layer 121, as the outermost layer, is directly attached to the inner wall of the outer sheath 11. Its loose structure can buffer the compressive stress of the outer sheath 11, preventing external impacts from being directly transmitted to the internal cable core 13 and the thermally conductive silicone tube 14. It also has good moisture absorption, preventing internal condensation from affecting electrical performance. The nylon braided layer 122 is located in the middle layer. Its crisscrossing braided structure enhances the tensile strength of the inner sheath 12, preventing the inner sheath 12 from tearing when the cable 1 is dragged or bent. It is also made of single-sided aluminum. The foil layer 123 provides a supporting skeleton to prevent the aluminum foil from breaking due to stretching. As the innermost layer, the single-sided aluminum foil layer 123 plays a core role in electromagnetic shielding. During fast charging, the high-frequency and high-current transmitted by the cable core 13 is prone to electromagnetic radiation. The single-sided aluminum foil layer 123 can improve the electromagnetic radiation shielding rate to more than 95%, avoiding interference with surrounding electronic devices. At the same time, it prevents external electromagnetic interference from affecting the current stability of the cable core 13. The three-layer structure is bonded together with environmentally friendly hot melt adhesive to form a seamless composite whole. This ensures the synergistic effect of each layer and avoids functional failure caused by layer separation, thus meeting the fast charging requirements of multi-core liquid-cooled cables for "high protection and anti-interference". As a further implementation of this solution, a guide rib 141 is fixedly connected to the inner wall of the thermally conductive silicone tube 14. The length of the guide rib 141 is the same as the length of the thermally conductive silicone tube 14, and the guide rib 141 is spirally arranged. It should be noted that the core of the guide rib 141 is to break the laminar flow of the coolant through the spiral structure, generate vortex, and improve the heat exchange efficiency. At the same time, the guide rib 141 can also enhance the rigidity of the thermal conductive silicone tube 14 and help the support component 15 maintain the shape of the thermal conductive silicone tube 14. As a further implementation of this scheme, multiple connecting support plates 153, supporting arc plates 154 and cable grooves 155 are arranged in a circular array, and multiple heat-conducting silicone tubes 14 and cable cores 13 are also arranged in a circular array. It should be noted that by maintaining the above-mentioned component shape, the circumferential array of the thermally conductive silicone tube 14 and the cable core 13 can be ensured to be precise. On the one hand, it ensures that each cable core 13 is subjected to uniform force, avoiding shape damage caused by uneven force. On the other hand, it ensures that the distance between each cable core 13 and the adjacent thermally conductive silicone tube 14 is consistent, ensuring uniform contact pressure and balanced thermal resistance distribution, preventing the decrease in thermal conductivity caused by increased local thermal resistance. At the same time, the circumferential array can also balance the impedance of the cable core 13, avoiding local overload heating caused by uneven current distribution. As a further implementation of this solution, the reset structure 156 includes a reset cavity 1561 symmetrically opened in the inner cavity of each connecting support plate 153. The inner cavity of the reset cavity 1561 is provided with a reset spring 1562. The two ends of the reset spring 1562 are fixedly connected to the inner end face of the reset cavity 1561 respectively. The inner cavity of the reset spring 1562 is symmetrically provided with reset support plates 1563. The ends of the two reset support plates 1563 that are far apart from each other are fixedly connected to the inner end face of the reset cavity 1561. The ends of the two reset support plates 1563 that are close to each other are fixedly connected with magnetic blocks 1564. There is a gap between the two magnetic blocks 1564, and the two magnetic blocks 1564 are set with the same magnetic pole. It should be noted that the reset spring 1562 and the magnetic block 1564 in the reset structure 156 are key to maintaining the shape of the support component 15: when the cable body 1 is bent or compressed, the elastic restoring force of the reset spring 1562 and the repulsive force of the same magnetic pole of the magnetic block 1564 can push the connecting support plate 153 to quickly restore its radial shape, avoiding long-term deformation of the support component. This shape-maintaining function ensures the stability of the inner cavity structure of the inner sheath 12 and prevents the cable core 13 from getting tangled (ensuring balanced current transmission) and the thermally conductive silicone tube. 14 is offset or squeezed (ensuring heat dissipation path); on the other hand, the cable core 13 is locked at the end of the supporting arc plate 154 to avoid relative displacement between the two, laying the foundation for subsequent anti-squeezing and heat conduction. The layout of the thermal conductive silicone tube 14 and the cable core 13 depends on the shape of the support component 15. If the shape of the support component is out of control, the thermal conductive silicone tube 14 will be squeezed, resulting in uneven contact pressure with the cable core 13, which will increase thermal resistance. It will also cause the coolant flow rate inside the tube to become unbalanced, forming a high temperature zone, which will seriously affect the heat dissipation efficiency during fast charging.

[0018] Workflow: Insert the support assembly 15 into the central thermally conductive silicone tube 14 (passing through the through hole 152) at certain intervals, and adjust the position of the support frame 151 to ensure uniform spacing. Then, place the remaining thermally conductive silicone tubes 14 on the supporting arc plate 154, using the arc surface of the supporting arc plate 154 and the inner wall of the inner sheath 12 for support and positioning, ensuring all thermally conductive silicone tubes 14 are in a circumferential array without compression deformation. Next, insert the multiple cable cores 13 into the cable grooves 155 formed by adjacent supporting arc plates 154. At this time, the ends of the supporting arc plates 154 are engaged on the outside of the cable cores 13 to prevent… The relative displacement of the cable core 13 and the thermally conductive silicone tube 14 ensures uniform contact pressure between the two. The assembled "support component 15-cable core 13-thermally conductive silicone tube 14" unit is then fitted into the inner sheath 12. The outer sheath 11 is then wrapped around the outside using an extruder. During the extrusion process, the pressure is controlled to prevent deformation of the inner sheath 12 and the support component 15, thus forming a complete cable body 1. Finally, end caps 2 are installed at both ends of the cable body 1. The crimping process ensures a tight connection between the end caps 2 and the cable core 13. At the same time, the connection between the end caps 2 and the cable body 1 is sealed to prevent coolant leakage and external moisture intrusion. Before charging, the cable body 1 is in a natural state, and the reset structure 156 of the support component 15 plays a role: the reset spring 1562 maintains the initial compression, and the repulsive force of the magnetic block 1564 ensures that the connecting support plate 153 maintains a radial shape, thereby allowing the support frame 151 and the supporting arc plate 154 to maintain the preset structure—the thermally conductive silicone tube 14 is not squeezed (the channel inside the tube is unobstructed), and the cable core 13 is stably positioned in the cable groove 155 (without offset), laying the foundation for current transmission and heat dissipation during charging. At the same time, the nylon braided layer 122 of the inner sheath 12 and the outer sheath 11 work together to resist slight external compression and prevent damage to the shape of the support component 15. When terminal 2 is connected to the fast charging device and the device being charged, the current is transmitted through the cable core 13. At this time, the cable core 13 generates heat due to the Joule effect. Since the support component 15 keeps the cable core 13 in a circumferential array, the impedance of each cable core 13 is balanced, the current distribution is uniform, and there is no local overload heating. The coolant is injected into the thermally conductive silicone tube 14 through the interface of terminal 2. Driven by the circulation pump, it flows along the thermally conductive silicone tube 14. When it flows through the spiral guide rib 141, the coolant generates eddies, breaks the laminar boundary layer, improves the heat exchange efficiency, and quickly absorbs the heat transferred from the cable core 13 to the tube wall. During this process, the supporting arc plate 154 of the support component 15 keeps the thermally conductive silicone tube 14 in shape, avoids the flow velocity imbalance caused by tube compression, and ensures uniform heat dissipation. When adjusting the position of the cable 1 during charging (such as dragging or bending), the connecting support plate 153 deforms as it bends, the return spring 1562 is compressed / stretched, the spacing of the magnetic blocks 1564 decreases and the repulsive force increases. The elastic restoring force of the return spring 1562 and the repulsive force of the magnetic blocks 1564 work together to push the connecting support plate 153 to quickly restore its radial shape, thereby allowing the support frame 151 and the supporting arc plate 154 to return to their initial positions—the thermally conductive silicone tube 14 is not offset and the cable core 13 is not tangled, ensuring that current transmission and heat dissipation are not interrupted. If the cable body 1 is subjected to external pressure, the non-woven fabric layer 121 of the outer sheath 11 and the inner sheath 12 buffers part of the pressure. The connecting support plate 153 of the support component 15 resists the remaining pressure through its own rigidity and in conjunction with the reset structure 156, maintaining a stable shape. At this time, the thermally conductive silicone tube 14 only undergoes slight deformation, and the guide rib 141 can still guide the coolant to flow normally, without the formation of local high temperature areas. The cable core 13 is protected by the supporting arc plate 154 in the cable groove 155, without compression deformation, and the resistance does not increase significantly. The high-frequency electromagnetic radiation generated by the cable core 13 during charging is shielded by the single-sided aluminum foil layer 123 of the inner sheath 12, avoiding interference with surrounding equipment. At the same time, the support component 15 keeps the cable core 13 evenly distributed, ensuring that the shielding effect of the single-sided aluminum foil layer 123 is uniform and there are no radiation leakage points.

[0019] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-core liquid-cooled charging cable structure, comprising a cable body (1) and end caps (2) disposed at both ends of the cable body (1), characterized in that: The cable body (1) includes an outer sheath (11), and an inner sheath (12) is provided inside the outer sheath (11). The inner cavity of the inner sheath (12) is provided with multiple cable cores (13) and thermally conductive silicone tubes (14). Multiple support components (15) are provided between the cable cores (13) and the thermally conductive silicone tubes (14). The multiple support components (15) are arranged at equal intervals. The support assembly (15) includes a support frame (151), with a through hole (152) for accommodating a thermally conductive silicone tube (14) through the center of the support frame (151). Multiple connecting support plates (153) are provided on the outer side of the support frame (151). Each of the multiple connecting support plates (153) is provided with a supporting arc plate (154) for supporting the thermally conductive silicone tube (14) at one end away from the support frame (151). A cable groove (155) for accommodating a cable core (13) is provided between adjacent supporting arc plates (154). A reset structure (156) is provided in the inner cavity of the connecting support plate (153). One of the thermally conductive silicone tubes (14) is inserted into the through hole (152), and the remaining multiple thermally conductive silicone tubes (14) are located at the supporting arc plate (154). Multiple cable cores (13) are respectively inserted into multiple cable grooves (155), and the end of the supporting arc plate (154) is locked on the outside of the cable core (13).

2. The multi-core liquid-cooled charging cable structure according to claim 1, characterized in that: The inner sheath (12) is a composite structure. The inner sheath (12) includes a non-woven fabric layer (121), a nylon filament braided layer (122) and a single-sided aluminum foil layer (123) from the outside to the inside. The non-woven fabric layer (121), the nylon filament braided layer (122) and the single-sided aluminum foil layer (123) are bonded to each other.

3. The multi-core liquid-cooled charging cable structure according to claim 1, characterized in that: The inner wall of the thermally conductive silicone tube (14) is fixedly connected with a guide rib (141). The length of the guide rib (141) is the same as the length of the thermally conductive silicone tube (14), and the guide rib (141) is spirally arranged.

4. The multi-core liquid-cooled charging cable structure according to claim 1, characterized in that: The multiple connecting support plates (153), supporting arc plates (154) and cable grooves (155) are arranged in a circular array, and the multiple thermally conductive silicone tubes (14) and cable cores (13) are also arranged in a circular array.

5. The multi-core liquid-cooled charging cable structure according to claim 1, characterized in that: The reset structure (156) includes reset cavities (1561) symmetrically opened in the inner cavity of each connecting support plate (153). The inner cavity of the reset cavity (1561) is provided with a reset spring (1562), and the two ends of the reset spring (1562) are fixedly connected to the inner end face of the reset cavity (1561).

6. The multi-core liquid-cooled charging cable structure according to claim 5, characterized in that: The inner cavity of the reset spring (1562) is symmetrically provided with reset support plates (1563), and the two reset support plates (1563) are fixedly connected to the inner end face of the reset cavity (1561) at their ends that are far apart from each other.

7. The multi-core liquid-cooled charging cable structure according to claim 6, characterized in that: The two reset support plates (1563) are fixedly connected to a magnetic block (1564) at one end close to each other. There is a gap between the two magnetic blocks (1564), and the two magnetic blocks (1564) are set with the same magnetic pole.

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