A charging cable for an electric vehicle

Abstract

The utility model discloses a charging cable for electric automobile, it includes the outer sheath for the protection of charging cable, the outer sheath inside sleeve joint has the heating cover of the cable of being convenient for cold region freezing and softening, the heating cover inner wall sleeve joint has the insulating layer, the insulating layer inner wall sleeve joint has the buffer cover of integrative forming, the inside of insulating layer is provided with the support buffer framework, this cable in the process of actual use, can through first coating enhancement coating guarantee adhesion and structural strength, coating hydrophobic low freezing point coating reduces icing again, is fit for long -term exposure in the outdoor public charging pile cable use, and it is in relatively cold area, this device is equipped with heating softening device still, reduces because temperature is low and causes the cable bending damage condition of the cable hardness being too high, secondly, the cable inside is provided with support buffer framework and buffer cover, can carry out certain support protection to the wire core and liquid cooling pipeline.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle charging cable technology, specifically a charging cable for electric vehicles. Background Technology

[0002] Electric vehicle charging cables are specialized cables used to connect electric vehicle charging devices to charging infrastructure for power transmission. They typically consist of a conductor, insulation layer, shielding layer, and sheath layer. The conductor is often made of copper, while the insulation and sheath layers are made of materials such as cross-linked polyethylene or thermoplastic elastomers, depending on the application and performance requirements. In addition, charging cables may also include a number of signal lines, control lines, and auxiliary power lines to ensure accurate control and safe operation throughout the charging process.

[0003] Existing electric vehicle charging cables, when used in extremely cold regions, present several challenges. Firstly, in areas with large nighttime temperature differences, moisture in the air easily condenses on the cable's outer sheath. This condensation quickly freezes into ice at low temperatures. This ice formation not only creates a hard ice layer on the sheath but also further hardens and embrittles the sheath material due to the combined effects of low temperature and ice encapsulation. This significantly reduces the cable's bending flexibility, making it prone to cracking or even breakage during subsequent insertion, removal, or cable handling, exposing the internal structure and posing safety hazards. Secondly, existing... The compression resistance design of charging cables is mostly concentrated on the outer sheath, which only buffers external pressure through the toughness of the sheath itself. However, key internal components lack targeted support, especially the liquid cooling pipes and cores in liquid-cooled cables. These two components are often loosely arranged inside the cable without an effective support structure. When the cable is squeezed, stepped on, or bent, the liquid cooling pipes and cores are prone to relative displacement, which can lead to mutual compression. This can cause deformation of the liquid cooling pipes and obstruction of coolant flow, reducing heat dissipation efficiency. In severe cases, it can damage the insulation layer of the cores, causing a short circuit risk and seriously affecting charging safety and cable lifespan. Utility Model Content

[0004] The purpose of this section is to outline some aspects of the embodiments of this utility model and to briefly introduce some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be used to limit the scope of this utility model.

[0005] In view of the problems existing in the above and / or existing electric vehicle charging cables, this utility model is proposed.

[0006] Therefore, the purpose of this utility model is to provide a charging cable for electric vehicles.

[0007] To solve the above-mentioned technical problems, according to one aspect of the present invention, the present invention provides the following technical solution: A charging cable for electric vehicles includes an outer sheath for protecting the charging cable, a heating sleeve inside the outer sheath for softening the cable in cold regions, an insulation layer inside the heating sleeve, an insulation layer inside the insulation layer, a buffer sleeve integrally formed on the inner circumference of the insulation layer, and a supporting buffer skeleton inside the insulation layer.

[0008] In a preferred embodiment of the electric vehicle charging cable of the present invention, the outer sheath is provided with a reinforcing coating on its outer circumference, and the reinforcing coating is provided with a hydrophobic coating on its outer circumference.

[0009] In a preferred embodiment of the electric vehicle charging cable described in this utility model, the heating sleeve has a heating wire wound around its outer circumference, and the inner circumference of the outer sheath has a matching spiral groove.

[0010] In a preferred embodiment of the electric vehicle charging cable of the present invention, a plurality of buffer sleeves are fitted with wire cores inside, and a plurality of buffer sleeves are arranged in a circumferential array on the inner wall of the circumference of the buffer sleeves.

[0011] In a preferred embodiment of the electric vehicle charging cable of this utility model, the supporting buffer skeleton is triangular, a heat dissipation gap is provided between the supporting buffer skeleton and the buffer sleeve, and a liquid cooling pipe is provided inside the heat dissipation gap.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: In actual use, the cable can first be coated with an reinforcing coating to ensure adhesion and structural strength, and then coated with a hydrophobic coating to reduce dew adhesion and freezing. It is suitable for use in public charging pile cables that are exposed outdoors for a long time. In colder regions, the device is also equipped with a heating and softening device to reduce the situation where the cable is bent and damaged due to excessive hardness caused by low temperature. Secondly, the cable is equipped with a support and buffer skeleton and a buffer sleeve inside, which can provide certain support and protection for the wire core and liquid cooling pipe, reducing the situation where multiple wire cores and liquid cooling pipes are squeezed and damaged by each other. Attached Figure Description

[0013] To more clearly illustrate the technical solutions of the embodiments of this utility model, the present utility model will be described in detail below with reference to the accompanying drawings and detailed embodiments. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] in: Figure 1 This is a schematic diagram of the overall structure of a charging cable for electric vehicles according to the present invention; Figure 2 This utility model relates to a charging cable for electric vehicles. Figure 1 A schematic diagram of the heating jacket structure in the middle; Figure 3 This utility model relates to a charging cable for electric vehicles. Figure 1 A schematic diagram of the structure of the outer sheath; Figure 4 This utility model relates to a charging cable for electric vehicles. Figure 3 A schematic diagram of structure A in the diagram; Figure 5 This utility model relates to a charging cable for electric vehicles. Figure 1 A schematic diagram showing the position of the wire cores.

[0015] Explanation of the numbers in the diagram: 100, outer sheath; 110, spiral groove; 120, reinforcing coating; 130, hydrophobic coating; 200, heating jacket; 210, heating wire; 220, insulation layer; 230, insulating layer; 240, buffer sleeve; 250, wire core; 260, supporting buffer frame. Detailed Implementation

[0016] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0017] Secondly, this utility model is described in detail with reference to the schematic diagrams. When describing the embodiments of this utility model, for ease of explanation, the cross-sectional views showing the device structure may be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of this utility model. In addition, in actual manufacturing, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0018] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be described in further detail below with reference to the accompanying drawings.

[0019] This utility model provides a charging cable for electric vehicles, including an outer sheath 100 for protecting the charging cable, a heating sleeve 200 for softening the cable in cold regions by being fitted inside the outer sheath 100, an insulation layer 220 for being fitted inside the inner wall of the heating sleeve 200, an insulation layer 230 for being fitted inside the inner wall of the insulation layer 220, a buffer sleeve 240 integrally formed on the inner circumference of the insulation layer 230, and a supporting buffer skeleton 260 provided inside the insulation layer 230.

[0020] Specifically, the outer sheath 100 is provided with a reinforcing coating 120 on its circumferential outer wall, and the reinforcing coating 120 is provided with a hydrophobic coating 130 on its circumferential outer wall.

[0021] In this embodiment: the outer sheath 100 serves as the outermost layer of protection for the cable and is made of low-temperature resistant polyurethane elastomer (TPU) material with a Shore hardness of 50D-60D, balancing scratch resistance and bending flexibility, and can withstand outdoor wind and sand, gravel impact, and the risk of embrittlement at low temperatures; a spiral groove 110 is formed on its inner circumference wall, and the pitch of the spiral groove 110 is adapted to the heating wire 210 on the outer wall of the heating sleeve 200, which is used to limit the installation position of the heating wire 210 and prevent the heating wire 210 from shifting during the heating process, causing local overheating; The reinforcing coating 120 is applied to the outer circumference of the outer sheath 100 with a thickness of 0.1-0.2 mm. It is made of a modified epoxy resin and glass microsphere composite system and is bonded to the outer sheath 100 through a thermosetting process. This can improve the tensile strength of the outer sheath 100 and enhance the surface wear resistance, thus preventing damage to the sheath caused by friction during long-term outdoor exposure.

[0022] Hydrophobic coating 130: Covers the outside of the reinforcing coating 120, with a thickness of 0.05-0.1mm. It is based on fluorocarbon resin and contains nano-silica hydrophobic additives. Its water contact angle is ≥115°, which can significantly reduce the amount of dew and snow on the cable surface. At the same time, a low freezing point modifier is incorporated into the coating, which can lower the freezing point of residual moisture on the surface to below -28°C, thereby reducing the hardening effect of low temperature freezing on the sheath from the source.

[0023] Specifically, the heating jacket 200 has an electric heating wire 210 wound around its outer circumference, and the outer sheath 100 has a matching spiral groove 110 on its inner circumference.

[0024] In this embodiment: the heating sleeve 200 is a tubular structure made of high-temperature resistant silicone rubber, coaxially sleeved inside the outer sheath 100, and an electric heating wire 210 is wound around its outer circumference along the spiral groove 110; the electric heating wire 210 is made of copper-nickel alloy wire with a diameter of 0.15mm and a single wire power density of 5W / m. The spiral winding achieves uniform heat distribution along the length of the cable, avoiding local temperature differences exceeding 5℃; the heating sleeve 200 and the outer sheath 100 are fixed together with high-temperature resistant pressure-sensitive adhesive to ensure that delamination will not occur due to thermal expansion and contraction in low-temperature environments; The insulation layer 220 is tightly fitted onto the inner wall of the heating jacket 200. It is made of polyimide foam material with a closed-cell structure, with a thickness of 1 to 1.5 mm and a thermal conductivity of ≤0.03 W / (m·K). This prevents the temperature from affecting the internal wire core 250.

[0025] Specifically, multiple buffer sleeves 240 have wire cores 250 inside, and multiple buffer sleeves 240 are arranged in a circumferential array on the inner wall of the circumference of the buffer sleeves 240.

[0026] Specifically, the support buffer frame 260 is triangular, and a heat dissipation gap is provided between the support buffer frame 260 and the aforementioned buffer sleeve 240. A liquid cooling pipe 270 is provided inside the heat dissipation gap.

[0027] In this embodiment: the insulation layer 230 is made of irradiated cross-linked polyethylene (XLPE) with a thickness of 2-2.5 mm and a voltage withstand strength ≥20 kV / mm. It can withstand a long-term operating temperature of 125°C, which can both block the leakage of internal current from the cable and resist temperature fluctuations during the heating process. Its inner circumference is integrally formed with a buffer sleeve 240 through injection molding to ensure the connection stability between the buffer sleeve 240 and the insulation layer 230 and prevent it from falling off when bending at low temperatures. The buffer sleeve 240 is made of low-hardness silicone rubber (Shore hardness 30D). Each buffer sleeve 240 is a tubular structure with open ends, and the internal coaxial sleeve is a wire core 250 (the wire core 250 is a multi-strand tinned copper wire stranded structure used to transmit charging current). Multiple buffer sleeves 240 are evenly distributed in an array along the inner circumference of the insulation layer 230. They absorb the stress of the wire core 250 when bending and squeezing through their own elastic deformation, preventing the insulation layer of the wire core 250 from being damaged. The support and buffer skeleton 260 has a triangular hollow structure and is injection molded from modified PP (polypropylene) material. The three support arms abut against the outer wall of the adjacent buffer sleeve 240 to form a stable triangular support system. Its function is to separate the buffer sleeves 240 corresponding to different wire cores 250, so as to prevent the wire cores 250 from colliding with each other when the cable is squeezed. At the same time, the hollow design reduces the impact on the flexibility of the cable and ensures that the skeleton can deform slightly with the overall structure when bent.

[0028] The liquid cooling pipe 270 is installed in the heat dissipation gap between the support buffer frame 260 and the buffer sleeve 240. The width of the heat dissipation gap is 3-5mm to ensure that there is enough space for the liquid cooling pipe 270 to be installed. The liquid cooling pipe 270 is made of low-temperature resistant fluoroplastic (FEP) material and is used to circulate low-temperature compatible coolant (such as ethylene glycol-water solution, freezing point ≤-40℃). It can quickly remove the heat generated by the core 250 during charging. Together with the heating sleeve 200, it forms a balanced system of "heating-insulation-heat dissipation" to avoid overheating or overcooling inside the cable.

[0029] In some embodiments, a signal line can be further installed in the heat dissipation gap inside the charging cable to further enhance the cable's functional integration and intelligent monitoring capabilities. Specifically, the signal line uses a low-temperature resistant polytetrafluoroethylene (PTFE) insulation layer and the conductor is a multi-strand fine copper wire stranded structure to adapt to the deformation requirements when the cable is bent. The signal line is arranged parallel to the length direction of the heat dissipation gap.

[0030] In this embodiment, to address the issues of icing, hardening, and internal compression in electric vehicle charging cables in frigid regions, the charging cable employs a triple design: outer protection, active heating, and internal support. For the outer protection layer, a double-layer coating process is used, consisting of a reinforcing coating 120 and a hydrophobic coating 130. The bottom reinforcing coating 120 is made of modified epoxy resin and bonded tightly to the outer sheath using a special cross-linking technology. This not only improves the adhesion of the sheath surface, preventing subsequent coating peeling, but also strengthens the overall structural strength of the sheath, resisting the scratches and impacts of outdoor wind, sand, and gravel. The surface is hydrophobic. The coating 130 incorporates nano-grade fluorocarbon resin and anti-icing agents, achieving a contact angle of over 110°. This significantly reduces the amount of dew adhering to the sheath surface and lowers the freezing point to below -25°C. Even if a small amount of dew remains overnight, it is unlikely to freeze, reducing the hardening effect of ice on the sheath from the source. Addressing the issue of cable material hardening and becoming easily bent and damaged in extremely cold environments, the cable also integrates a low-temperature adapted heating and softening device. Ultra-fine copper-nickel alloy heating wires 210 are evenly embedded between the outer sheath 100 and the heating sleeve 200, working in conjunction with... An NTC temperature sensor, positioned 1 meter apart, monitors the sheath temperature in real time. When the ambient temperature drops below -15℃, the heating wire automatically activates low-power heating (5-8W / m), maintaining the sheath temperature above -5℃ through uniform heat conduction. This restores the material's flexibility and prevents cracks or breakage during manual bending. The heating device uses a 12V low-voltage power supply, drawing power from the charging pile's low-voltage interface, combining safety and energy efficiency. Internally, the cable features a built-in support buffer skeleton 260 and buffer sleeve 240 combination structure. The 60 is injection molded with modified TPU elastomer, forming a support between the core 250 and the liquid cooling pipe 270. This not only avoids direct contact between the core and the pipe, but also buffers external extrusion impact through the elastic deformation of the support buffer skeleton 260 itself, reducing the amount of pipe deformation during extrusion and ensuring smooth flow of coolant. Through this internal support design, it can effectively prevent the core 250 and the liquid cooling pipe 270 from being displaced or damaged by extrusion when the cable is squeezed by external forces such as being stepped on or collided, thus ensuring the heat dissipation stability and conductivity safety during the charging process.

[0031] Although the present invention has been described above with reference to embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the present invention. In particular, as long as there is no structural conflict, the features in the embodiments disclosed in this invention can be combined with each other in any way. The lack of an exhaustive description of these combinations in this specification is merely for the sake of brevity and resource conservation. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A charging cable for electric vehicles, characterized in that, The device includes an outer sheath (100) for protecting the charging cable, inside which is a heating sleeve (200) for softening the cable in cold regions. The inner wall of the heating sleeve (200) is fitted with an insulation layer (220), the inner wall of the insulation layer (220) is fitted with an insulation layer (230), the inner wall of the insulation layer (230) is integrally formed with a buffer sleeve (240), and a supporting buffer skeleton (260) is provided inside the insulation layer (230).

2. The charging cable for electric vehicles according to claim 1, characterized in that, The outer sheath (100) is provided with a reinforcing coating (120) on its circumferential outer wall, and the reinforcing coating (120) is provided with a hydrophobic coating (130) on its circumferential outer wall.

3. The charging cable for electric vehicles according to claim 1, characterized in that, The heating sleeve (200) has an electric heating wire (210) wound around its outer circumference, and the outer sheath (100) has a matching spiral groove (110) on its inner circumference.

4. A charging cable for electric vehicles according to claim 1, characterized in that, Multiple buffer sleeves (240) are fitted with wire cores (250) inside, and multiple buffer sleeves (240) are arranged in a circumferential array on the inner wall of the circumference of the buffer sleeves (240).

5. A charging cable for electric vehicles according to claim 1, characterized in that, The support buffer frame (260) is triangular, and a heat dissipation gap is provided between the support buffer frame (260) and the buffer sleeve (240). A liquid cooling pipe (270) is provided inside the heat dissipation gap.

Images