Laminated flat core cable

Abstract

The application relates to a laminated flat-core cable, which improves the heat dissipation environment inside the cable through structural design of laminated conductors, greatly increases the heat dissipation area relative to a traditional multi-strand cable, and effectively improves the electric core heat dissipation characteristics inside the cable; the same cross-sectional area of copper core can pass through a larger current under the same temperature control condition, that is, a larger carrying capacity is achieved, or the same passing current of the copper core can reduce the amount of the copper core under the same temperature control condition, thereby saving copper materials, that is, the material cost is reduced; the laminated quantity and laminated mode of the single-layer conductors can be adjusted according to application requirements, which not only is easy to produce and prepare, but also makes the laminated flat-core cable flexible to use and adapt to the requirements of various different specifications of cables; through design of the position, quantity and size of the gap, different requirements of various heat dissipation capacities can be adapted, and in cooperation with the design of the abutting convex part, the gap can be effectively maintained to achieve the heat dissipation effect of the design target.

Description

Technical Field

[0001] This application relates to the field of cables, and in particular to laminated flat core cables. Background Technology

[0002] Copper is an important strategic resource used in many industries. The cores of power cables are also a major user of copper.

[0003] The general curve of current carrying capacity versus copper core cross-sectional area for copper core power cables is as follows: Figure 1 As shown, the unit of cross-sectional area is square millimeters. Figure 1 It can be seen that the current carrying capacity of a copper core cable with a cross-sectional area of ​​10 square millimeters can reach about 6A per square millimeter, while the current carrying capacity of a copper core cable with a cross-sectional area of ​​50 square millimeters is only 3A per square millimeter, and it decreases as the area increases.

[0004] Analysis revealed that the main reason is that the heat dissipation of the battery core in traditional power cables is affected by the traditional structure of the battery core. The cross-sectional structure of traditional power cables, such as... Figure 2 As shown, in multi-strand wires such as multi-strand stranded wires, both the internal and external cells generate heat during operation. However, when the external cell dissipates heat, it is heated by itself and also by the internal cell. Since the internal cell is surrounded by the external cell, the heat dissipation environment is poor, and the heat cannot be dissipated, that is, the heat dissipation of the internal cell is hindered.

[0005] The maximum permissible temperature of the battery core in a power cable is typically required to be no higher than 70°C. Furthermore, as the core temperature increases, its resistance also increases, leading to increased line loss. Therefore, the heat dissipation characteristics of the battery core are a crucial factor affecting the current-carrying capacity of high-current cables. Utility Model Content

[0006] Therefore, it is necessary to provide a laminated flat core cable.

[0007] One embodiment of this application is a laminated flat core cable, which includes a laminated conductor and an insulating covering layer covering the laminated conductor;

[0008] The stacked conductor includes at least one stacked single-layer conductor, and the stacked conductor has a gap between two adjacent single-layer conductors;

[0009] Along the length of the laminated flat core cable, the cross-section of the single-layer conductor has a flat shape with an aspect ratio greater than 5;

[0010] Furthermore, the single-layer conductor has an abutting protrusion to abut against other single-layer conductors and maintain the gap.

[0011] The aforementioned laminated flat core cable, through its structural design of the laminated conductors, effectively improves the internal heat dissipation environment of the cable and significantly increases the heat dissipation area compared to traditional multi-strand stranded cables, thereby effectively enhancing the heat dissipation characteristics of the internal conductors. Furthermore, it allows copper cores of the same cross-sectional area to carry a larger current under the same temperature control conditions, achieving a greater current carrying capacity, or it allows for a reduction in the amount of copper core used under the same temperature control conditions, thus saving copper and reducing material costs. Moreover, the number and stacking method of single-layer conductors can be adjusted according to application requirements, making it easy to manufacture and adaptable to various cable specifications. Finally, by designing the position, number, and size of the gaps, it can accommodate different heat dissipation requirements, and the design of the abutment protrusions effectively maintains the gaps to achieve the designed heat dissipation effect.

[0012] In some embodiments, the monolayer conductor also has a structural recess, which serves at least partially as the gap when the monolayer conductor abuts against another monolayer conductor via the abutting protrusion.

[0013] In some embodiments, the structural recess is configured to have a different shape than the abutting protrusion; or, the structural recess is configured to have a different size than the abutting protrusion.

[0014] In some embodiments, along the length of the laminated flat core cable, the cross-sectional area of ​​the structural recess is smaller than the cross-sectional area of ​​the abutting protrusion; or, the cross-sectional area of ​​the structural recess is larger than the cross-sectional area of ​​the abutting protrusion.

[0015] In some embodiments, in two adjacent monolayer conductors, the abutting protrusion in one monolayer conductor abuts against the abutting protrusion in the other monolayer conductor, and the structural recess in one monolayer conductor and the structural recess in the other monolayer conductor together form the gap; or...

[0016] In two adjacent monolayer conductors, the abutting protrusion in one monolayer conductor abuts against the structural recess in the other monolayer conductor, and a gap is formed in the structural recess.

[0017] In some embodiments, the single-layer conductor has a body and abutting protrusions protruding from the body, the abutting protrusions being annularly surrounding the body, and the number of abutting protrusions being at least two; or,

[0018] Along the length of the laminated flat core cable, the cross-section of the single-layer conductor has a flat shape with an aspect ratio greater than 10.

[0019] In some embodiments, the insulating covering layer includes a covering layer covering the laminated conductors and an insulating layer disposed outside the covering layer.

[0020] In some embodiments, the covering layer is disposed around the laminated conductor in a wrapping manner; or, the covering layer is formed on the laminated conductor in an extrusion manner.

[0021] In some embodiments, the insulating covering layer further includes a shielding layer disposed outside the insulating layer.

[0022] In some embodiments, the insulating covering layer further includes a protective layer disposed outside the shielding layer. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a general curve showing the relationship between the current carrying capacity and the cross-sectional area of ​​the copper core in a copper-core power cable.

[0025] Figure 2 This is a schematic diagram of the multi-strand structure of a traditional power cable.

[0026] Figure 3 This is a schematic diagram of the structure of the first embodiment of the laminated flat core cable described in this application.

[0027] Figure 4 for Figure 3 The illustrated embodiment is shown in an exploded view.

[0028] Figure 5 for Figure 3 Another schematic diagram of the embodiment shown.

[0029] Figure 6 This is a schematic diagram of the structure of the second embodiment of the laminated flat core cable described in this application.

[0030] Figure 7 for Figure 6 A schematic diagram of the structure of the multilayer conductor in the embodiment shown.

[0031] Figure 8 for Figure 7 Another schematic diagram of the embodiment shown.

[0032] Figure 9 for Figure 8Another schematic diagram of the embodiment shown.

[0033] Figure 10 This is a schematic diagram of the structure of the laminated conductor in the third embodiment of the laminated flat core cable described in this application.

[0034] Figure 11 This is a schematic diagram of the structure of the laminated conductor in the fourth embodiment of the laminated flat core cable described in this application.

[0035] Figure 12 for Figure 11 A schematic diagram of a single-layer conductor in the embodiment shown.

[0036] Figure 13 This is a structural schematic diagram of the fifth embodiment of the laminated flat core cable described in this application.

[0037] Figure 14 for Figure 13 A schematic diagram of the structure of the multilayer conductor in the embodiment shown.

[0038] Figure 15 This is a schematic diagram of the sixth embodiment of the laminated flat core cable described in this application.

[0039] Figure 16 This is a structural schematic diagram of the seventh embodiment of the laminated flat core cable described in this application.

[0040] Figure 17 for Figure 16 A schematic diagram of the structure of the multilayer conductor in the embodiment shown.

[0041] Figure 18 This is a schematic diagram of the eighth embodiment of the laminated flat core cable described in this application.

[0042] Reference numerals: 100 for laminated flat core cable, 200 for laminated conductor, 300 for insulating sheath, 400 for length direction, L for length, W for width;

[0043] First conductor 201, second conductor 202, third conductor 203, fourth conductor 204, first abutting protrusion 205, second abutting protrusion 206, single-layer conductor 210, abutting protrusion 211, structural recess 212, body 213, gap 220, void 230, connecting section 240, covering layer 310, insulating layer 320, shielding layer 330, and protective layer 340. Detailed Implementation

[0044] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0045] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on the other component or there may be an intermediate component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intermediate component present. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application's specification are for illustrative purposes only and do not represent the only possible implementation.

[0046] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0047] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature and the second feature are in indirect contact through an intermediate medium. Furthermore, "above," "over," and "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0048] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and or" as used in this application includes any and all combinations of one or more of the associated listed items.

[0049] This application discloses a laminated flat core cable, which includes some or all of the technical features of the following embodiments; that is, the laminated flat core cable includes some or all of the following structures. In one embodiment of this application, a laminated flat core cable includes a laminated conductor and an insulating covering layer covering the laminated conductor; the laminated conductor includes at least one stacked single-layer conductor, and the laminated conductor has a gap between two adjacent single-layer conductors; in the length direction of the laminated flat core cable, the cross-section of the single-layer conductor has a flat shape with an aspect ratio greater than 5; and the single-layer conductor has an abutting protrusion to abut against other single-layer conductors to maintain the gap. The aforementioned laminated flat core cable, through its structural design of the laminated conductors, effectively improves the internal heat dissipation environment of the cable and significantly increases the heat dissipation area compared to traditional multi-strand stranded cables, thereby effectively enhancing the heat dissipation characteristics of the internal conductors. Furthermore, it allows copper cores of the same cross-sectional area to carry a larger current under the same temperature control conditions, achieving a greater current carrying capacity, or it allows for a reduction in the amount of copper core used under the same temperature control conditions, thus saving copper and reducing material costs. Moreover, the number and stacking method of single-layer conductors can be adjusted according to application requirements, making it easy to manufacture and adaptable to various cable specifications. Additionally, by designing the position, number, and size of the gaps, it can accommodate different heat dissipation requirements, and the design of the abutment protrusions effectively maintains the gaps to achieve the designed heat dissipation effect. The following section will combine... Figures 3 to 15 The laminated flat core cable is described in detail below.

[0050] In some embodiments, a laminated flat core cable 100, such as Figure 3 As shown, it includes a multilayer conductor 200 and an insulating covering layer 300 covering the multilayer conductor 200; combined with Figure 4 and Figure 5 The stacked conductor 200 includes at least one stacked single-layer conductor 210, and the stacked conductor 200 has a gap 220 between two adjacent single-layer conductors 210; Figure 4 and Figure 5 In the illustrated embodiment, the laminated conductor 200 includes two stacked single-layer conductors 210; and, along the length direction 400 of the laminated flat core cable 100, the cross-section of the single-layer conductor 210 has a flat shape with an aspect ratio greater than 5; combined with Figure 7 and Figure 10 The ratio of the length L to the width W of the cross section of the single-layer conductor 210 is greater than 5; and the single-layer conductor 210 has an abutting protrusion 211 to abut against other single-layer conductors 210 to maintain the gap 220.

[0051] This structural design, through the structural design of the laminated conductor 200, effectively improves the internal heat dissipation environment of the cable and greatly increases the heat dissipation area compared to traditional multi-strand stranded cables, thereby effectively improving the heat dissipation characteristics of the internal core. On the other hand, it allows copper cores of the same cross-sectional area to carry a larger current under the same temperature control conditions, that is, to achieve a larger current carrying capacity, or allows copper cores of the same carrying capacity to be used in a smaller amount under the same temperature control conditions, thereby saving copper materials and reducing material costs. Furthermore, the number and stacking method of the single-layer conductors 210 can be adjusted according to application requirements, which is not only easy to manufacture, but also makes the laminated flat core cable 100 flexible in use and adaptable to the needs of various cable specifications. Moreover, by designing the position, number and size of the gaps 220, it can adapt to different heat dissipation requirements, and with the design of the abutment protrusions 211, it can effectively maintain the gaps 220 to achieve the heat dissipation effect of the design target.

[0052] In some of these embodiments, such as Figure 2 and Figure 3 As shown, the insulating covering layer 300 includes a covering layer 310 covering the laminated conductor 200, and an insulating layer 320 disposed outside the covering layer 310. As an example, Figure 2 and Figure 3 In the illustrated embodiment, the insulating sheath 300 further includes a shielding layer 330 disposed outside the insulating layer 320 to enhance the mechanical strength of the cable and improve its shielding effectiveness. The shielding layer 330 can also be called an armor layer and can be made of aluminum alloy; generally, any non-magnetic metal strip can be used as the shielding layer 330. In some embodiments, such as... Figure 6 or Figure 18 As shown, the insulating sheath 300 also includes a protective layer 340 disposed outside the shielding layer 330. For example, the protective layer 340 is made of PVC, PE, or fluoroplastics. For example, other layers, such as a reinforcing layer or a protective layer, can be added outside the protective layer 340. For instance, to resist rodent bites, termites, etc., and to prevent the cable from being dragged in harsh environments, a thin nylon layer can be added outside the PVC sheath as a protective layer.

[0053] This structural design, on the one hand, by layering the sheathing layer 310, insulation layer 320, and shielding layer 330, ensures the basic insulation performance of the laminated conductor 200 while effectively enhancing the mechanical strength of the laminated flat core cable 100 using the shielding layer 330 made of non-magnetic metal strips such as aluminum alloy. It also significantly improves the cable's shielding effectiveness against electromagnetic interference, preventing the external electromagnetic environment from affecting the conductor's transmission performance. On the other hand, the protective layer 340 added outside the shielding layer 330, made of suitable materials such as PVC, PE, or fluoroplastics, provides basic protection for the cable's core structure, resisting wear and environmental corrosion during daily use. Furthermore, for specific scenario requirements, a reinforcing layer or protective layer can be flexibly superimposed on the protective layer 340. For example, a thin nylon layer can be added on the outside of the PVC sheath to specifically resist rodent bites and termite damage, while preventing the cable from being dragged in harsh environments, greatly expanding the applicable scenarios of the laminated flat core cable 100. On the other hand, the materials and structures of each layer can be flexibly adjusted according to actual application requirements. There is no need to modify the main structure of the laminated conductor 200, and different protection, shielding or mechanical strength requirements can be quickly adapted through layer combination, taking into account both production convenience and product applicability, further enhancing the comprehensive use value of the laminated flat core cable 100.

[0054] In some embodiments, the covering layer 310 is wrapped around the multilayer conductor 200. For example, the covering layer 310 is wrapped around the multilayer conductor 200 with a wrapping angle of 40 to 80 degrees, an overlap rate of 20% to 40%, and 1 to 3 wrapping layers. For example, the covering layer 310 is wrapped around the multilayer conductor 200 with a wrapping angle of 50 to 75 degrees and an overlap rate of 20% to 30%. For example, a low-smoke halogen-free elastomer high flame-retardant wrapping tape or a halogen-free flame-retardant nonwoven fabric tape is used to wrap two layers around the multilayer conductor 200, one in the forward direction and one in the reverse direction, with an overlap rate of 25%. The purpose of the wrapping is to facilitate the multilayer conductor 200 (e.g., stacked copper strip) in subsequent extrusion processes and to protect the heat dissipation surface of the single-layer conductor 210 (e.g., copper strip). In some embodiments, the overlay 310 is formed outside the stacked conductor 200 by extrusion; as an example, the overlay 310 is formed outside the stacked conductor 200 by extrusion, and the extrusion direction is the length direction 400.

[0055] This structural design, on the one hand, surrounds the laminated conductor 200 by wrapping, and specifies the parameters of the wrapping angle (30 to 60 degrees), the wrapping overlap rate (20% to 40%), and the number of wrapping layers (1 to 3). This ensures a tight fit between the covering layer 310 and the laminated conductor 200, while preventing deformation of the laminated conductor 200 due to excessive wrapping. At the same time, the reasonable overlap rate and number of layers prevent gaps in the wrapping, ensuring uniform wrapping of the laminated conductor 200. In particular, when using low-smoke halogen-free elastomer high flame-retardant wrapping tape or halogen-free flame-retardant non-woven fabric tape, with one layer in each direction and one in the opposite direction and an overlap rate of 25%, it can not only adapt to the subsequent extrusion process and prevent the copper strips in the laminated conductor 200 from shifting or being damaged during processing, but also protect the heat dissipation surface of the copper strips in the single conductor 210, without affecting the heat dissipation channel originally formed by the gap 220 of the laminated conductor 200, thus ensuring the heat dissipation characteristics of the laminated flat core cable 100. On the other hand, an extrusion method is provided as a supplement to the wrapping method. The sheath 310 is extruded along the length direction 400 onto the outside of the laminated conductor 200. This process enables continuous production of the sheath 310, improves processing efficiency, and the extruded sheath 310 has a denser structure, which can further enhance the protective effect on the laminated conductor 200 and reduce the impact of the external environment on the conductor. The two processes can be flexibly selected according to actual production needs and application scenarios without changing the core structure of the laminated flat core cable 100. This reduces the cost of process adjustment and meets the requirements of the sheath 310 for fit, protection and production efficiency in different scenarios, further improving the applicability and production flexibility of the product.

[0056] As an example, such as Figure 4 and Figure 5 As shown, the abutting protrusion 211 also abuts against the insulating covering layer 300 to form a gap 230 between the multilayer conductor 200 and the insulating covering layer 300, thereby improving the heat dissipation effect of the conductor structure at the outer edge of the multilayer conductor 200. As an example, the abutting protrusion 211 can be formed by first manufacturing the single-layer conductor 210 and then by indentation, or it can be formed directly during the manufacturing process using a mold. It should be noted that in all embodiments, the abutting protrusion 211 is a structure with a smooth surface, not a burr. Taking the indentation process as an example, the conductor material of the single-layer conductor 210 can be Ti soft copper.

[0057] This structural design, on the one hand, maintains the gap 220 between adjacent single-layer conductors 210 and the insulating coating layer 300 by simultaneously abutting the protrusion 211, and also forms a gap 230 between the laminated conductor 200 and the insulating coating layer 300. This creates heat dissipation channels in both the inner and outer areas of the laminated conductor 200, especially enhancing the heat dissipation effect at the outer edge of the laminated conductor 200, further optimizing the overall heat dissipation environment of the laminated flat core cable 100, and ensuring its temperature control stability under high current conditions. On the other hand, it provides two processing methods: pre-producing the conductor and then indenting, and direct molding with a mold, flexibly adapting to different production needs. The indentation process can precisely process the abutment protrusion 211 based on the formed single-layer conductor 210, using Ti soft copper as the conductor material, which has both good conductivity and processing ductility. Direct molding with a mold simplifies the production process and improves efficiency. Furthermore, it is clearly stated that the abutting protrusion 211 is a smooth surface structure rather than a burr, so as to avoid scratching the insulating covering layer 300 or damaging the integrity of the gap 220 and the void 230.

[0058] To facilitate increased heat dissipation area and cable flexibility through layered design, in some embodiments, such as Figure 7 and Figure 8 As shown, there are two single-layer conductors 210, namely a first conductor 201 and a second conductor 202. The first conductor 201 and the second conductor 202 are arranged adjacent to each other. When the insulating covering layer 300 covers the laminated conductors 200, there is a gap 220 between the first conductor 201 and the second conductor 202. The gap 220 is not filled with any other material, that is, it retains air, so as to facilitate heat dissipation of the conductor structure located in the middle position. In some embodiments, such as Figure 10 As shown, there are four single-layer conductors 210, namely the first conductor 201, the second conductor 202, the third conductor 203, and the fourth conductor 204. These conductors are stacked, i.e., layered, with a gap 220 between adjacent single-layer conductors 210. It is understood that a wider contact surface between the single-layer conductor 210, such as a copper strip, and the outside environment results in better heat dissipation. However, due to limitations in construction and switchgear connections, it is more reasonable and feasible to produce using a multi-strip stacking method. This method is easy to produce, convenient for construction, does not occupy space in cable trays and electrical control systems, and is compatible with high-current air switch connections.

[0059] This structural design serves two purposes. Firstly, for the scheme with two single-layer conductors 210, by placing them adjacent to each other and leaving a gap 220 without filler material after the insulation layer 300 is applied, air is retained within the gap 220. Compared to the traditional solid core design, the conductor structure in the middle position is relatively easier to dissipate heat. Simultaneously, the flat structure of the single-layer conductor 210 itself allows the conductor structure in the middle position to quickly conduct heat through the gap 220, ensuring both heat dissipation efficiency and meeting the design goal of increasing the heat dissipation area. Secondly, for the stacked scheme with four single-layer conductors 210, by placing gaps 220 between adjacent single-layer conductors 210, the contact area between the conductor and the air is further increased. Furthermore, the stacked structure does not disrupt the flat characteristics of the single-layer conductor 210, maintaining good heat dissipation capabilities. On the other hand, whether it is a design with two or four single-layer conductors 210, the core structural logic of the laminated flat core cable 100 remains unchanged. By simply adjusting the number and stacking method of the single-layer conductors 210, it can be adapted to different current scenarios and installation environments, further improving the product's flexibility and adaptability to different scenarios, and perfectly meeting the comprehensive design requirements that take into account heat dissipation, production and construction.

[0060] In some of these embodiments, such as Figure 8 and Figure 12 As shown, the single-layer conductor 210 also has a structural recess 212, so that when the single-layer conductor 210 abuts against another single-layer conductor 210 through the abutting protrusion 211, the structural recess 212 at least partially serves as the gap 220. For example, when the single-layer conductor 210 abuts against another single-layer conductor 210 through the abutting protrusion 211, the structural recess 212 partially serves as the gap 220. Alternatively, when the single-layer conductor 210 abuts against another single-layer conductor 210 through the abutting protrusion 211, the structural recess 212 entirely serves as the gap 220. For example, the gap 220 between two adjacent single-layer conductors 210 includes a combined shape or structure of the two structural recesses 212 belonging to the two single-layer conductors 210.

[0061] This structural design, on the one hand, by setting structural recesses 212 on the single-layer conductor 210, allows it to use part or all of the area of ​​the structural recesses 212 as gaps 220 when it abuts against other single-layer conductors 210 via the abutting protrusions 211. This eliminates the need to reserve additional blank space between adjacent single-layer conductors 210, thus precisely constructing a heat dissipation channel. This ensures the stable existence of the gaps 220 and avoids the overall looseness of the laminated conductor 200 structure due to improper design of the gaps 220, improving the compactness and stability of the internal structure of the laminated flat core cable 100. On the other hand, the gaps 220 between two adjacent single-layer conductors 210 can be formed by combining two structural recesses 212. This design allows for flexible adjustment of the shape and size of the gaps 220. For example, by changing the depth, width, or contour of the structural recesses 212, different heat dissipation requirements can be met without making significant modifications to the structure of the abutting protrusions 211, reducing design and production adjustment costs. Meanwhile, the synergistic effect of the structural recess 212 and the abutting protrusion 211 allows the single-layer conductor 210 to form a stable structure with the protrusion positioning and the recess heat dissipation when stacked. This ensures that adjacent single-layer conductors 210 will not block the heat dissipation path due to excessive tightness, and also avoids conductor displacement that could damage the gap 220, further guaranteeing the heat dissipation performance and structural reliability of the laminated flat core cable 100.

[0062] To avoid the gap 220 being far below design requirements due to the structural recess 212 of the dissimilar single-layer conductor 210 fitting into the abutting protrusion 211, in some embodiments, such as Figure 12 As shown, the structural recess 212 and the abutting protrusion 211 have different shapes, that is, the shape of the structural recess 212 and the shape of the abutting protrusion 211 are different, and the same will not be repeated below; in some embodiments, the structural recess 212 and the abutting protrusion 211 have different sizes; in some embodiments, the structural recess 212 and the abutting protrusion 211 have different shapes and different sizes.

[0063] This structural design, on the one hand, fundamentally avoids the interlocking of structural recesses 212 and abutment protrusions 211 between dissimilar single-layer conductors 210. For example, by setting different shapes, the two cannot form a matching interlocking structure; or by setting different sizes, even if there is positional overlap, they cannot fit tightly; or by setting both different shapes and sizes, the possibility of interlocking is further blocked. This effectively prevents the gap 220 from being squeezed and reduced to a level far below the design requirements due to interlocking, ensuring the dimensional stability of the gap 220, ensuring the effective space of the heat dissipation channel inside the laminated conductor 200, and maintaining the heat dissipation performance expected by the design of the laminated flat core cable 100. On the other hand, this differentiated design does not require additional complex positioning structures or processing steps. It can be achieved simply by adjusting the shape and size parameters of the structural recesses 212 and abutment protrusions 211. It does not affect the production efficiency of the single-layer conductor 210, nor does it change the overall stacking logic of the laminated conductor 200. Meanwhile, a stable gap 220 can prevent the local temperature of the laminated flat core cable 100 from becoming too high due to the failure of the heat dissipation channel, thereby ensuring the stability of the cable's current carrying capacity, or reducing copper loss under the same current carrying capacity, and improving the reliability of product performance.

[0064] To further prevent the structural recess 212 of the dissimilar single-layer conductor 210 from fitting with the abutting protrusion 211, resulting in a gap 220 that is far below the design requirements, in some embodiments, the structural recess 212 is combined with... Figure 9 and Figure 12 Along the length direction 400 of the laminated flat core cable 100, the cross-sectional area of ​​the structural recess 212 is smaller than the cross-sectional area of ​​the abutting protrusion 211; or, in other embodiments, the cross-sectional area of ​​the structural recess 212 is larger than the cross-sectional area of ​​the abutting protrusion 211.

[0065] This structural design, on the one hand, further prevents the possible fitting of the structural recess 212 and the abutment protrusion 211 of the dissimilar single-layer conductors 210 from a dimensional perspective. Whether the cross-sectional area of ​​the structural recess 212 is smaller than that of the abutment protrusion 211, preventing the abutment protrusion 211 from being embedded in the recess, or the cross-sectional area of ​​the structural recess 212 is larger than that of the abutment protrusion 211, preventing the two from forming a tightly fitted fitting structure, it can effectively prevent the gap 220 from being squeezed and reduced to a level far below the design requirements due to fitting, ensuring the effective space of the gap 220, ensuring the integrity of the internal heat dissipation channel of the laminated conductor 200, and maintaining the heat dissipation performance expected by the design of the laminated flat core cable 100. On the other hand, the above design does not require additional complex processing steps, and can be achieved simply by adjusting the cross-sectional dimensions of the structural recess 212 and the abutment protrusion 211 on the single-layer conductor 210, which does not affect the production efficiency of the single-layer conductor 210, nor does it change the stacking logic of the laminated conductor 200. Meanwhile, a stable gap 220 can prevent the laminated flat core cable 100 from overheating due to insufficient heat dissipation, thereby ensuring the stability of the cable's current carrying capacity, or reducing the amount of copper material used under the same current carrying capacity.

[0066] The gap 220 can be implemented in various ways, but the purpose is to enhance the heat dissipation capability of the single-layer conductor 210 in the middle region. In some embodiments, such as Figure 4 and Figure 8 As shown, in two adjacent single-layer conductors 210, the abutting protrusion 211 in one single-layer conductor 210 abuts against the abutting protrusion 211 in the other single-layer conductor 210, and the structural recess 212 in one single-layer conductor 210 and the structural recess 212 in the other single-layer conductor 210 together form the gap 220; or, in some embodiments, such as Figure 11 As shown, in two adjacent single-layer conductors 210, the abutting protrusion 211 in one single-layer conductor 210 abuts against the structural recess 212 in the other single-layer conductor 210, and the gap 220 is formed in the structural recess 212.

[0067] This structural design, on the one hand, allows for flexible adjustment of the overall size of the gap 220 through the combination of two structural recesses 212, and the mutual abutment of the protrusions 211 ensures stable spacing between adjacent single-layer conductors 210, preventing deformation or blockage of the gap 220 due to conductor displacement. This provides ample heat dissipation channels for the single-layer conductors 210 in the middle region of the laminated conductors 200, effectively dissipating heat and ensuring the heat dissipation performance of the laminated flat core cable 100. Alternatively, on the other hand, heat dissipation space can be constructed using only a single structural recess 212 without relying on the cooperation of two structural recesses 212, simplifying the stacking logic of the single-layer conductors 210. At the same time, the precise abutment of the protrusions 211 and the structural recesses 212 can both fix the conductor position and ensure the effective size of the gap 220, which can also enhance the heat dissipation capacity of the single-layer conductors 210 in the middle region. On the other hand, neither of the above two gap 220 implementation methods changes the core structure of the laminated flat core cable 100. It can be flexibly selected according to the production process, heat dissipation requirements and conductor specifications. It does not require the addition of complex components, and can ensure the achievement of heat dissipation goals, further improving the production flexibility and scenario adaptability of the product. At the same time, the stable gap 220 design also provides reliable support for the laminated flat core cable 100 to maintain a large current carrying capacity and reduce copper material costs.

[0068] In some of these embodiments, such as Figure 12 As shown, the single-layer conductor 210 has a body 213 and an abutting protrusion 211 protruding from the body 213. The abutting protrusion 211 is annularly surrounding the body 213, and the number of abutting protrusions 211 is at least two. In various embodiments, such as Figure 10 As shown, in the length direction of the laminated flat core cable, the cross-section of the single-layer conductor has a flat shape with an aspect ratio greater than 5. For example, in the length direction 400 of the laminated flat core cable 100, the cross-section of the single-layer conductor 210 has a flat shape with an aspect ratio greater than 10, that is, in the length direction 400, the ratio of the length L to the width W of the cross-section of the single-layer conductor 210 is greater than 10. Other embodiments follow the same principle and will not be elaborated further. For example, in the length direction 400, the ratio of the length L to the width W of the cross-section of the single-layer conductor 210 is 10 to 50; for example, in the length direction 400, the ratio of the length L to the width W of the cross-section of the single-layer conductor 210 is 12 to 25, such as 12.5 to 25.

[0069] This structural design, on the one hand, by setting the body 213 and the annular abutment protrusions 211 protruding from the body 213, and the number of abutment protrusions 211 is at least two, the annular structure can make the contact between the abutment protrusions 211 and other single-layer conductors 210 more uniform, avoiding conductor displacement caused by local stress. At the same time, multiple annular abutment protrusions 211 can form multi-point support around the body 213, further enhancing the structural stability of the stacked conductors 200 after stacking, effectively maintaining the gap 220 between adjacent single-layer conductors 210, ensuring that the heat dissipation channel is not squeezed and deformed, and ensuring the stability of the internal heat dissipation environment of the stacked flat core cable 100. On the other hand, it is clear that the aspect ratio of the single-layer conductor 210 in the length direction 400 of the laminated flat core cable 100 is greater than 5, or even greater than 10, that is, the ratio of the cross-sectional length L to the width W is greater than 10. This flat shape with a high aspect ratio greatly increases the contact area between the single-layer conductor 210 and the air compared with the traditional round or low aspect ratio conductors. Especially when the stacked arrangement is used, the flat surface of each single-layer conductor 210 can participate in heat dissipation, which significantly improves the overall heat dissipation efficiency of the laminated conductor 200. At the same time, the flat structure is more suitable for the stacked design, which can realize the close stacking of multiple conductors in a limited space. It does not occupy additional laying space, and can increase the total cross-sectional area of ​​the conductor through the multi-layer stacking method, providing a basis for the laminated flat core cable 100 to achieve a large current carrying capacity, or reducing the amount of copper material used under the same current carrying capacity, thus reducing material costs. On the other hand, the combination structure of the body 213 and the annular abutment protrusion 211, combined with the flat design with a high aspect ratio, not only ensures the structural strength of the single-layer conductor 210, but also does not affect its conductivity. Moreover, it can be integrally formed by mold during production, which is simple and easy to achieve, further improving the production convenience and product consistency of the laminated flat core cable 100.

[0070] To ensure the stability of the gap 220 while using a relatively large number of single-layer conductors 210 to increase current carrying capacity, for example, such as Figure 13 and Figure 14 As shown, in some embodiments, the multilayer conductor 200 further includes connecting segments 240, which connect to each of the single-layer conductors 210 respectively, and both ends of the connecting segments 240 abut against the insulating covering layer 300 to provide support in the width direction of the single-layer conductors 210 and enhance the maintenance effect of the gap 220; as an example, the connecting segments 240 are also used to increase the gap 230 to improve the heat dissipation effect of the conductor structure at the outer edge of the multilayer conductor 200. As an example, the connecting segments 240 are integrally formed with each of the single-layer conductors 210. Along the length direction 400 of the multilayer flat core cable 100, Figure 13 The illustrated embodiment shows the laminated flat core cable 100 with a flat shape, such as a rounded rectangle. In other embodiments, the laminated flat core cable 100 may also be circular or elliptical. Figure 15 or Figure 18 As shown.

[0071] This structural design, on the one hand, by adding connecting sections 240, connects each single-layer conductor 210 and abuts against the insulating covering layer 300 at both ends, forming a stable support in the width direction of the single-layer conductor 210. Even if a relatively large number of single-layer conductors 210 are used to increase the current carrying capacity, the connecting sections 240 can effectively limit the displacement or deformation of each single-layer conductor 210, and prevent the gap 220 from being squeezed and damaged due to excessive conductor stacking, thereby ensuring the dimensional stability of the gap 220, ensuring the integrity of the heat dissipation channel inside the laminated conductor 200, and maintaining high-efficiency heat dissipation performance. At the same time, the connecting sections 240 can also increase the gap 230, further widening the heat dissipation path at the outer edge of the laminated conductor 200, strengthening the heat dissipation effect of the outer edge conductor structure, and avoiding local heat accumulation. On the other hand, the design of the connector 240 and each single-layer conductor 210 being integrally formed eliminates the need for additional assembly processes. This simplifies the production process of the laminated conductor 200, improves processing efficiency, and ensures the connection strength between the connector 240 and the single-layer conductor 210, preventing structural stability from being affected by assembly gaps. Furthermore, the laminated flat core cable 100 offers various shape options, including flat, round, and elliptical, allowing for flexible adaptation to different laying environments. It meets diverse construction needs without modifying the core structure, greatly enhancing the product's adaptability to various scenarios. Moreover, the above design increases current carrying capacity without sacrificing heat dissipation performance, and through structural optimization, it balances production convenience and installation flexibility, ensuring stable performance even in multi-conductor, high-current-carrying scenarios, thus broadening its application range.

[0072] For embodiments with connection segment 240, in order to improve the heat dissipation capacity of the conductor structure located in the middle position, as an example, such as Figure 16 and Figure 17 As shown, in some embodiments, the connecting segment 240 connects two adjacent monolayer conductors 210 to space them apart, thereby increasing the gap 220, and the abutting protrusion 211 abuts against the connecting segment 240 to maintain the gap 220 by abutting against other monolayer conductors 210 through the connecting segment 240.

[0073] This structural design, on the one hand, directly increases the spatial size of the gap 220 by connecting two adjacent single-layer conductors 210 and spacing them apart. The larger gap 220 can accommodate more air, accelerating airflow and carrying away heat from the middle position of the laminated conductors 200, significantly improving the heat dissipation capacity of the conductor structure in the middle area, avoiding heat accumulation in the middle area due to conductor stacking, and further optimizing the overall heat dissipation environment of the laminated flat core cable 100. On the other hand, by using the abutting protrusion 211 to abut the connecting section 240, and then indirectly abutting other single-layer conductors 210 through the connecting section 240, a stable support structure of protrusion, connecting section, and conductor is formed. This avoids direct contact and blockage of the gap 220 by adjacent single-layer conductors 210, and maintains the increased size of the gap 220 through the supporting effect of the connecting section 240, preventing the gap 220 from deforming due to external pressure on the cable. Furthermore, the above design can be achieved only through the coordinated cooperation of the connecting section 240 and the abutting protrusion 211, without changing the core production logic of the laminated conductor 200, thus balancing heat dissipation improvement and structural stability.

[0074] In each embodiment, the laminated flat core cable 100 replaces the traditional multi-strand copper core with a flat copper core having abutment protrusions 211, which can increase the heat dissipation area of ​​the battery core, allowing a larger current to pass through the copper core with the same cross-sectional area. The following is based on... Figure 3 The following is a comparative test conducted on Example 1 shown.

[0075] Comparative Example 1: Using a traditional 120 square millimeter battery cell, the load current is 240A, the ambient temperature is 27.5℃, the current carrying time is 30 minutes, and the measured cell temperature at the last time is 44.5℃.

[0076] Example 1: Using a 120 mm² flat battery cell, with a load current of 315 A, an ambient temperature of 27.5 °C, and a current-carrying time of 30 minutes, the measured cell temperature at the end of the time was 44.8 °C.

[0077] The above comparative tests show that using flat cells can increase the current carrying capacity by about 30%, and the cell temperatures are very similar.

[0078] The following is a comparison test of copper consumption and current carrying capacity, as shown in the table below.

[0079] The current carrying capacity data of bare core cables under the same cross-sectional area (copper loss) are shown in Table 1 below.

[0080]

[0081] Table 1

[0082] The cross-sectional area data of the bare core of the cable under the same current carrying capacity are shown in Table 2 below.

[0083]

[0084] Table 2

[0085] In each test comparison example, the laminated flat core cable 100 adopts a flat conductor structure design. As mentioned above, under the premise of using the same amount of material as the core, the current carrying capacity can be increased by 30% compared with the traditional round cable; if only the same current carrying capacity is required, the material can be reduced by up to 20% compared with the traditional round cable. Moreover, the single-layer conductor 210 can be stacked and embedded in 2 to 3 layers or even more, which is easy to manufacture.

[0086] It should be noted that other embodiments of this application also include, as well as, implementable laminated flat core cables formed by combining the technical features of the above embodiments.

[0087] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0088] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. Therefore, the patent protection scope of this application should be determined by the appended claims.

Claims

1. A laminated flat core cable (100), characterized in that, It includes a multilayer conductor (200) and an insulating covering layer (300) covering the multilayer conductor (200). The stacked conductor (200) includes at least one stacked single-layer conductor (210), and the stacked conductor (200) has a gap (220) between two adjacent single-layer conductors (210). Along the length direction (400) of the laminated flat core cable (100), the cross-section of the single-layer conductor (210) has a flat shape with an aspect ratio greater than 5; Furthermore, the single-layer conductor (210) has an abutting protrusion (211) to abut against other single-layer conductors (210) to maintain the gap (220).

2. The laminated flat core cable (100) according to claim 1, characterized in that, The monolayer conductor (210) also has a structural recess (212) such that, in the state where the monolayer conductor (210) abuts against another monolayer conductor (210) by the abutting protrusion (211), the structural recess (212) at least partially serves as the gap (220).

3. The laminated flat core cable (100) according to claim 2, characterized in that, The structural recess (212) and the abutting protrusion (211) are configured with different shapes; or, the structural recess (212) and the abutting protrusion (211) are configured with different sizes.

4. The laminated flat core cable (100) according to claim 2, characterized in that, Along the length direction (400) of the laminated flat core cable (100), the cross-sectional area of ​​the structural recess (212) is smaller than the cross-sectional area of ​​the abutting protrusion (211); or, the cross-sectional area of ​​the structural recess (212) is larger than the cross-sectional area of ​​the abutting protrusion (211).

5. The laminated flat core cable (100) according to claim 2, characterized in that, In two adjacent monolayer conductors (210), the abutting protrusion (211) in one monolayer conductor (210) abuts against the abutting protrusion (211) in the other monolayer conductor (210), and the structural recess (212) in one monolayer conductor (210) and the structural recess (212) in the other monolayer conductor (210) together form the gap (220); or, In two adjacent monolayer conductors (210), the abutting protrusion (211) in one monolayer conductor (210) abuts against the structural recess (212) in the other monolayer conductor (210), and the gap (220) is formed in the structural recess (212).

6. The laminated flat core cable (100) according to claim 1, characterized in that, The single-layer conductor (210) has a body (213) and abutting protrusions (211) protruding from the body (213). The abutting protrusions (211) are arranged in a ring around the body (213), and the number of abutting protrusions (211) is at least two; or, Along the length direction (400) of the laminated flat core cable (100), the cross-section of the single-layer conductor (210) has a flat shape with an aspect ratio greater than 10.

7. The laminated flat core cable (100) according to any one of claims 1 to 6, characterized in that, The insulating covering layer (300) includes a covering layer (310) covering the multilayer conductor (200) and an insulating layer (320) disposed outside the covering layer (310).

8. The laminated flat core cable (100) according to claim 7, characterized in that, The covering layer (310) is disposed around the multilayer conductor (200) in a wrapping manner; or the covering layer (310) is formed around the multilayer conductor (200) in an extrusion manner.

9. The laminated flat core cable (100) according to claim 7, characterized in that, The insulating covering layer (300) further includes a shielding layer (330) disposed outside the insulating layer (320).

10. The laminated flat core cable (100) according to claim 9, characterized in that, The insulating covering layer (300) also includes a protective layer (340) disposed outside the shielding layer (330).

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