A rigid cable

Abstract

The utility model discloses a rigid cable, include: at least one rigid conductor, the rigid conductor inside has the liquid cooling channel of setting along its axial through -going, metal sheath, the outer periphery of rigid conductor is covered, first insulating layer, set up the outer periphery of metal sheath, through above -mentioned technical scheme, set up liquid cooling channel in rigid conductor, through the circulation coolant in liquid cooling channel, the heat of producing in the rigid conductor work in cable is taken away fast, reduces cable temperature rise, guarantees the cooling effect of cable to the greatest extent to improve the current -carrying capacity and life of cable.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and more specifically, to a rigid cable. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the driving range of electric vehicles is constantly improving, and the battery capacity is also increasing. This necessitates increasing charging power to achieve fast charging and address the charging speed issue. Increasing the charging current is a common method for achieving high-power charging, but the inherent resistance of the conductor material leads to increased overall heat dissipation in the cable. The most basic way to reduce heat dissipation is to increase the wire diameter, but this increases the cable's size and weight. Moreover, with further increases in charging current, simply increasing the wire diameter is no longer feasible.

[0003] Therefore, based on years of experience and practice in related industries, the inventor has proposed a rigid cable that cools the conductor by setting up a liquid cooling channel inside the rigid conductor, thereby overcoming the defects of the prior art. Utility Model Content

[0004] One objective of this invention is to provide a new technical solution for rigid cables.

[0005] According to a first aspect of the present invention, a rigid cable is provided, comprising:

[0006] At least one rigid conductor, wherein the rigid conductor has a liquid cooling channel extending through it along its axial direction; A metal sheath is fitted around the outer periphery of the rigid conductor. A first insulating layer is disposed on the outer periphery of the metal sheath.

[0007] Optionally, the rigid cable has at least one bend along its axial direction, and the liquid cooling channel remains continuous within the bend.

[0008] Optionally, there may be multiple bends, and the multiple zigzag segments formed by the multiple bends of the rigid cable are located in different planes.

[0009] Optionally, the number of rigid conductors is two, and the two rigid conductors are arranged in parallel.

[0010] Optionally, the liquid cooling channels of the two rigid wires are connected in series at the same end through a connecting pipe, so that the other end of the liquid cooling channel of one rigid wire forms a liquid inlet and the other end of the liquid cooling channel of the other rigid wire forms a liquid outlet.

[0011] Optionally, the connecting pipe is configured as a long pipe that is inserted into a liquid-cooled channel of one of the rigid wires through a liquid inlet, then through a liquid-cooled channel of another rigid wire, and exits through a liquid outlet.

[0012] Optionally, it may also include a wrapping layer, which is spirally wound around the outer periphery of the rigid conductor and located between the rigid conductor and the metal sheath.

[0013] Optionally, the rigid conductor includes a hollow rigid conductor, a second insulating layer, and a fiber braided protective layer arranged radially outward in sequence.

[0014] Optionally, the first insulating layer is constructed as a high-temperature resistant insulating varnish coated on the outer periphery of the metal sheath.

[0015] Optionally, the metal sheath is integrally fitted around the periphery of at least one rigid conductor or an integral structure formed by multiple rigid conductors; or, the metal sheath includes a plurality of sub-sheaths arranged sequentially along its axial direction, with adjacent sub-sheaths connected by welding.

[0016] According to the rigid cable disclosed herein, the following advantages are achieved: The rigid cable in this application is equipped with a rigid conductor, and a liquid cooling channel is provided in the rigid conductor. By circulating coolant in the liquid cooling channel, the heat generated by the rigid conductor in the cable during operation is quickly removed, reducing the temperature rise of the cable and maximizing the cooling effect of the cable, thereby improving the current carrying capacity and service life of the cable.

[0017] Other features and advantages of the present invention will become clear from the following detailed description of exemplary embodiments of the present invention with reference to the accompanying drawings. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the present invention and, together with their description, serve to explain the principles of the present invention.

[0019] Figure 1 A schematic diagram of the structure of the rigid cable according to a preferred embodiment of this utility model; Figure 2 Another structural schematic diagram of the rigid cable provided in the preferred embodiment of this utility model; Figure 3 Another structural schematic diagram of the rigid cable provided in the preferred embodiment of this utility model.

[0020] The diagram is marked as follows: 101-Rigid conductor; 102-Liquid cooling channel; 103-Metal sheath; 104-First insulation layer; 105-Connecting pipe; 106-Wrapping layer; 107-Hollow rigid conductor; 108-Second insulation layer; 109-Fiber braided protective layer; 110-Bending part; 111-Liquid inlet; 112-Liquid outlet. Detailed Implementation

[0021] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the present invention.

[0022] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0023] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0024] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0025] According to a rigid cable of this disclosure, such as Figures 1 to 3 As shown, it includes: At least one rigid conductor 101, wherein the rigid conductor 101 has a liquid cooling channel 102 that extends through it along its axial direction; A metal sheath 103 is fitted around the outer periphery of the rigid conductor 101; The first insulating layer 104 is disposed on the outer periphery of the metal sheath 103.

[0026] The rigid cable in this application is provided with a rigid conductor 101, and a liquid cooling channel 102 is provided in the rigid conductor 101. By circulating coolant in the liquid cooling channel 102, the heat generated by the rigid conductor 101 in the cable during operation is quickly removed, reducing the temperature rise of the cable and maximizing the cooling effect of the cable, thereby improving the current carrying capacity and service life of the cable.

[0027] The metal sheath 103 provides excellent waterproof, shielding, and mechanical protection.

[0028] According to one embodiment of a rigid cable disclosed herein, the rigid cable is provided with at least one bend 110 along its axial direction, and the liquid cooling channel 102 remains continuous within the bend 110.

[0029] The rigid cable in this application can be prefabricated to a predetermined shape. By bending the rigid cable into the predetermined shape using a bending device, a standard accessory can be formed, which facilitates the installation of the cable by operators in vehicles, charging piles, or other equipment that requires the flow of high current. This simplifies the installation process. Furthermore, because the rigid cable is rigid and has already been formed into a predetermined shape, it avoids the cable from becoming tangled in vehicles, charging piles, or other equipment that requires the flow of high current, keeping it neat and tidy.

[0030] Specifically, there are multiple bending portions 110, and the multiple zigzag segments formed by the multiple bending portions 110 of the rigid cable are located in different planes.

[0031] By setting multiple bends 110 in the rigid cable, the rigid cable can be adapted to the wiring path of the vehicle, charging pile or other equipment that needs to carry a large current, making it easier for operators to assemble the cable later.

[0032] According to one embodiment of a rigid cable disclosed herein, the number of rigid conductors 101 is two, and the two rigid conductors 101 are arranged in parallel.

[0033] In practical implementation, the rigid cable incorporates two rigid conductors 101. These two conductors serve as a positive power conductor connecting to the positive terminal of the power supply and a negative power conductor connecting to the negative terminal. Coolant circulates within a liquid-cooling channel 102 inside the rigid conductors 101, dissipating the heat generated by the positive and negative power conductors during operation. This maximizes the cooling effect of the cable, thereby improving its current-carrying capacity and service life.

[0034] Specifically, the liquid cooling channels 102 of the two rigid wires 101 are connected in series at the same end through a connecting pipe 105, so that the other end of the liquid cooling channel 102 of one rigid wire 101 forms a liquid inlet 111, and the other end of the liquid cooling channel 102 of the other rigid wire 101 forms a liquid outlet 112.

[0035] By connecting the liquid cooling channels 102 in the two rigid wires 101 through the connecting pipe 105, a loop is formed. This allows the coolant to enter the liquid cooling channel 102 of one rigid wire 101 through the inlet 111 of the liquid cooling circulation pump, then flow through the connecting pipe 105 into the liquid cooling channel 102 of the other rigid wire 101, and then return to the liquid cooling circulation pump through the outlet 112, thereby realizing the circulation of the coolant.

[0036] In practice, the connecting pipe 105 is constructed as an insulating pipe made of insulating material.

[0037] Specifically, the connecting pipe 105 is configured as a long pipe that is inserted into the liquid cooling channel 102 of one of the rigid wires 101 through the liquid inlet 111, and then exits through the liquid cooling channel 102 of another rigid wire 101 and through the liquid outlet 112.

[0038] By constructing the connecting pipe 105 as a long pipe that passes through the liquid cooling channel 102 of one rigid wire 101 and the liquid cooling channel 102 of another rigid wire 101, it is easier to connect the liquid cooling channel 102 and the rigid wire 101, and the safety is also higher. This avoids the rigid wire 101 from short-circuiting and causing danger when it is used as a positive power wire and a negative power wire.

[0039] According to one embodiment of a rigid cable disclosed herein, it further includes a wrapping layer 106, which is spirally wound around the outer periphery of the rigid conductor 101 and located between the rigid conductor 101 and the metal sheath 103.

[0040] In practice, the wrapping tape is wrapped around the outside of at least two rigid conductors 101 to secure and fix multiple rigid conductors 101, making the multiple rigid conductors 101 a whole, so as to facilitate the installation of other structures in the cable later.

[0041] The wrapping layer 106 can be selected from one or more of the following as needed: polyester film (PET), polyimide film (PI), mica tape, glass fiber cloth / tape, aramid fiber tape, plastic woven tape (such as PP, PE), metal composite tape (such as copper tape, aluminum tape), silicone tape, hot melt adhesive tape, semi-conductive tape / self-adhesive rubber tape.

[0042] According to one embodiment of a rigid cable disclosed herein, the rigid conductor 101 includes a hollow rigid conductor 107, a second insulation layer 108, and a fiber braided protective layer 109 arranged radially outward in sequence.

[0043] Hollow rigid conductor 107 has the following advantages compared to stranded conductor: Under high-frequency alternating current, current tends to concentrate on the surface (outer sheath) of the conductor, with the current density at the center of the conductor being almost zero; this is known as the "skin effect." The advantage of hollow conductors is that they not only do not reduce the effective conductive area, but also allow the conductive material to be used in the area where the current actually flows, saving raw materials and reducing cable weight. Furthermore, when rigid cables are used as high-voltage cables, the hollow portion of the hollow rigid conductor 107 can serve as a liquid cooling channel 102, allowing coolant to circulate. The circulating coolant removes the heat generated by the hollow rigid conductor 107, further ensuring the cable's cooling effect, reducing temperature rise, and thus improving the cable's current-carrying capacity and service life.

[0044] The hollow rigid conductor 107 has better thermal conductivity. The hollow part of the hollow rigid conductor 107 serves as a liquid cooling channel 102, through which coolant can circulate. The circulation of the coolant carries away the heat generated when the hollow rigid conductor 107 is used as a positive and negative power conductor, further ensuring the cooling effect of the cable, reducing the temperature rise of the cable, and thus improving the current carrying capacity and service life of the cable.

[0045] The fiber braided protective layer 109 is formed by weaving polyester fibers or polyester filaments, which can buffer the pressure generated when the outer metal sheath 103 is bent and protect the second insulation layer 108.

[0046] The hollow rigid conductor 107 has a certain degree of flexibility and can be wound onto a large-diameter spool without damaging its physical structure.

[0047] According to one embodiment of a rigid cable of the present disclosure, the first insulation layer 104 is configured as a high-temperature resistant insulating varnish coated on the outer periphery of the metal sheath 103.

[0048] By applying high-temperature insulating varnish to the outer periphery of the metal sheath 103, the high-temperature resistant insulating varnish can adhere tightly to the metal surface, forming a continuous, dense, and non-porous film. This effectively isolates the metal sheath 103 from contact with various corrosive media such as moisture, oxygen, chemical solvents, and salt spray, thereby extending the service life of the cable in vehicles, charging sockets, and other or other equipment that requires the flow of large currents.

[0049] High-temperature resistant insulating varnishes can be selected from silicone resin insulating varnishes, polyamide-imide, epoxy-modified silicone resin, polyimide, inorganic coatings, or other materials, depending on the requirements.

[0050] The metal sheath 103 is integrally sleeved on the outer periphery of at least one rigid conductor 101 or an integral structure formed by multiple rigid conductors 101; or, the metal sheath 103 includes multiple sub-sheaths arranged sequentially along its axial direction, and adjacent sub-sheaths are connected by welding.

[0051] The metal sheath 103 can be a hollow tube made of aluminum or aluminum alloy. Multiple rigid conductors 101 are wrapped with a wrapping tape to form an integral structure. During the extrusion process of the hollow aluminum tube, the integral structure formed by the wrapping tape serves as the internal core and passes through the hollow tube by synchronous traction.

[0052] Alternatively, multiple rigid conductors 101 can be cut to a predetermined length, then arranged in parallel and wrapped with a wrapping tape to form an integral structure, and then manually inserted into a hollow tube of a predetermined length.

[0053] The sub-sleeves can be prefabricated in sections at the factory, facilitating transportation and on-site assembly, making them particularly suitable for long-distance, large-span, or space-constrained laying environments. Welded connections allow for flexible adjustments in complex paths such as bends, turns, and branches, reducing the rigidity limitations of the overall metal sheath 103. The metal sheath 103 expands and contracts with temperature changes; the segmented welded structure creates micro-deformation zones at the weld seams, effectively releasing thermal stress and preventing cracking or deformation of the entire sheath due to concentrated thermal stress. This is especially suitable for environments with large temperature differences and drastic diurnal / seasonal variations. If a section of the metal sheath 103 is damaged (e.g., due to corrosion or mechanical damage), that section can be replaced individually, eliminating the need to replace the entire sheath and reducing maintenance costs.

[0054] Although specific embodiments of the present invention have been described in detail by way of examples, those skilled in the art should understand that the above examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. A rigid cable, characterized in that, include: At least one rigid conductor, wherein the rigid conductor has a liquid cooling channel extending through it along its axial direction; A metal sheath is fitted around the outer periphery of the rigid conductor; A first insulating layer is disposed on the outer periphery of the metal sheath.

2. The rigid cable according to claim 1, characterized in that, The rigid cable has at least one bend along its axial direction, and the liquid cooling channel remains continuous within the bend.

3. The rigid cable according to claim 2, characterized in that, The number of bends is multiple, and the multiple zigzag segments formed by the multiple bends of the rigid cable are located in different planes.

4. The rigid cable according to claim 1, characterized in that, The number of rigid conductors is two, and the two rigid conductors are arranged in parallel.

5. The rigid cable according to claim 4, characterized in that, The liquid cooling channels of the two rigid wires are connected in series on the same side by a connecting pipe, so that the other end of the liquid cooling channel of one rigid wire forms a liquid inlet and the other end of the liquid cooling channel of the other rigid wire forms a liquid outlet.

6. The rigid cable according to claim 5, characterized in that, The connecting pipe is constructed as a long pipe that is inserted into a liquid-cooled channel of one of the rigid wires through a liquid inlet, then through a liquid-cooled channel of another rigid wire, and exits through a liquid outlet.

7. The rigid cable according to claim 1, characterized in that, It also includes a wrapping layer, which is spirally wound around the outer periphery of the rigid conductor and located between the rigid conductor and the metal sheath.

8. The rigid cable according to claim 1, characterized in that, The rigid conductor comprises a hollow rigid conductor arranged radially outward, a second insulating layer, and a fiber braided protective layer.

9. The rigid cable according to claim 1, characterized in that, The first insulating layer is constructed as a high-temperature resistant insulating varnish coated on the outer periphery of the metal sheath.

10. The rigid cable according to claim 1, characterized in that, The metal sheath is integrally fitted around the periphery of at least one rigid conductor or an integral structure formed by multiple rigid conductors; or, the metal sheath includes multiple sub-sheaths arranged sequentially along its axial direction, with adjacent sub-sheaths connected by welding.

Images