New energy high-flexibility pressure-resistant fireproof charging pile cable
Patent Information
- Application Number
- CN202522117761.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-30
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-09-30
AI Technical Summary
Existing charging pile cables lack flexibility, the conductors are prone to breakage, the insulation layer is prone to aging and breakdown, they have poor fire resistance, and there is a risk of leakage under high voltage conditions. They also have weak environmental resistance and abrasion resistance, resulting in low safety.
It adopts a concentric twisted structure of seven strands of tin-plated copper wire and one strand of aramid fiber core, combined with a sheath layer of modified TPU, polycaprolactone and nano silica. The fire-retardant layer uses glass fiber-basalt fiber mixed woven tape and halogen-free low smoke flame-retardant tape. The insulation layer uses cross-linked polyethylene and thermoplastic elastomer. The structure of each layer works together to improve flexibility, pressure resistance and fire resistance.
It achieves high flexibility, pressure resistance and fire resistance of the cable, meets the needs of charging piles, avoids conductor strand breakage, insulation layer breakdown and release of toxic gases, and improves safety and wear resistance.
Smart Images
Figure CN224934520U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of fireproof technology for charging pile cables, specifically, to a new energy high-flexibility, pressure-resistant, fireproof charging pile cable. Background Technology
[0002] With the promotion of new energy sources, the application of new energy electric vehicles is becoming increasingly widespread, and the construction of charging piles is also increasing. Therefore, the future prospects of charging pile cables are broad, and the demand for charging pile cables used in electric vehicles will inevitably increase significantly. Furthermore, with the popularization of fast charging technology and the expansion of diverse charging scenarios such as outdoor and on-board charging, the requirements for the high flexibility, pressure resistance, and fire resistance of cables are becoming more stringent, further driving the market demand for high-quality charging pile cables.
[0003] Most existing charging pile cables lack flexibility, with conductors often being solid or simply stranded. The insulation and sheath layers are rigid, making them prone to breakage and cracking with frequent bending, resulting in short lifespans. Furthermore, the insulation layers are mostly single-layered ordinary materials, susceptible to breakdown due to electrical treeing under high-voltage fast-charging conditions, posing a risk of leakage. Secondly, their fire resistance is poor, often using halogen-containing flame-retardant materials that release toxic gases during combustion, causing rapid flame spread and low safety. Thirdly, they have weak environmental resistance and abrasion resistance, easily becoming brittle at low temperatures, aging easily outdoors, and easily breaking after dragging and friction. Therefore, those skilled in the art provide a new energy high-flexibility, high-voltage, fire-resistant charging pile cable to solve the problems mentioned in the background. Utility Model Content
[0004] The purpose of this utility model is to provide a new energy high-flexibility, pressure-resistant, fire-resistant charging pile cable to solve the problems mentioned in the background art above.
[0005] This utility model provides the following technical solution: a new energy high-flexibility pressure-resistant fireproof charging pile cable, including a sheath layer structure. The inner wall of the sheath layer structure is provided with a fireproof and flame-retardant layer for blocking the spread of flames and inhibiting the release of toxic gases to achieve fire safety protection. The inner wall of the fireproof and flame-retardant layer is provided with an insulation layer structure for withstanding high voltage and isolating current to avoid leakage and breakdown. The insulation layer structure contains seven strands of tin-plated copper wire for transmitting electrical energy and ensuring stable current conduction. The insulation layer structure also contains a strand of aramid fiber core for preventing the copper wires from twisting and breaking.
[0006] As a preferred embodiment of the above technical solution, the seven strands of tin-plated copper wire and the single strand of aramid fiber core are in a concentric twisted structure, the diameter of the seven strands of tin-plated copper wire is 0.1-0.3mm, and the diameter of the single strand of aramid fiber core is 0.1mm.
[0007] As a preferred embodiment of the above technical solution, the sheath layer structure includes modified TPU, polycaprolactone, and nano-silica, wherein the mass percentage of polycaprolactone is 10-15%, the mass percentage of nano-silica is 5%, and the overall thickness of the sheath layer structure is 0.6-1mm.
[0008] As a preferred embodiment of the above technical solution, the sheath layer structure further includes a spiral groove, the depth of which is 0.5-1mm and the pitch is 5-10mm.
[0009] As a preferred embodiment of the above technical solution, the fireproof and flame-retardant layer comprises a glass fiber-basalt fiber mixed woven tape and a halogen-free low-smoke flame-retardant tape. The glass fiber-basalt fiber mixed woven tape has a mixing ratio of glass fiber to basalt fiber of 3:7, and the single filament diameter of the fiber used in the woven tape is 8-10μm. The overall thickness of the fireproof and flame-retardant layer is 0.4-0.6mm.
[0010] As a preferred embodiment of the above technical solution, the insulation layer structure includes a thermoplastic elastomer and cross-linked polyethylene, wherein the thickness of the thermoplastic elastomer layer is 0.4-0.6 mm and the thickness of the cross-linked polyethylene layer is 0.8-1 mm.
[0011] Compared with the prior art, the beneficial effects of this utility model are:
[0012] This utility model of a high-flexibility, pressure-resistant, fire-resistant charging pile cable for new energy uses a conductor structure composed of seven strands of tin-plated copper wire and one strand of aramid fiber core to transmit electrical energy. The aramid fiber core ensures that the conductor is not prone to breakage when frequently bent. The cross-linked polyethylene layer in the insulation layer structure withstands high voltage and isolates current, while the thermoplastic elastomer layer enhances the flexibility of the insulation layer. The fire-retardant layer, through the synergistic effect of halogen-free low-smoke flame-retardant tape and glass fiber-basalt fiber mixed braided tape, blocks the spread of flames and inhibits the release of toxic gases. The sheath layer structure not only achieves wear resistance and low-temperature resistance through the combination of modified TPU, polycaprolactone, and nano-silica, but its inner wall spiral grooves also reduce bending friction and assist in heat dissipation. The cooperation of each layer structure gives the cable the characteristics of high flexibility, pressure resistance, and fire resistance, making it suitable for the usage scenarios of charging piles. Attached Figure Description
[0013] Figure 1 A three-dimensional structural diagram of a new energy high-flexibility, pressure-resistant, fire-resistant charging pile cable;
[0014] Figure 2 A schematic diagram of a spiral groove connection for a new energy high-flexibility, pressure-resistant, fire-resistant charging pile cable;
[0015] Figure 3 A schematic diagram of the sheath material composition of a new energy high-flexibility, pressure-resistant, fire-resistant charging pile cable;
[0016] Figure 4 This is a schematic diagram of the material composition of the fireproof and flame-retardant layer and the insulation layer.
[0017] In the diagram: 1. Sheath layer structure; 11. Modified TPU; 12. Polycaprolactone; 13. Nano-silica; 14. Spiral groove; 2. Fire-retardant layer; 21. Glass fiber-basalt fiber mixed woven tape; 22. Halogen-free low-smoke flame-retardant tape; 3. Insulation layer structure; 31. Thermoplastic elastomer; 32. Cross-linked polyethylene; 4. Tinned copper wire; 5. Aramid fiber core. Detailed Implementation
[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.
[0019] Please see Figure 1 As shown, this utility model provides a technical solution: a new energy high-flexibility pressure-resistant fireproof charging pile cable, including a sheath layer structure 1. The inner wall of the sheath layer structure 1 is provided with a fireproof and flame-retardant layer 2 for blocking the spread of flames and inhibiting the release of toxic gases to achieve fire safety protection. The inner wall of the fireproof and flame-retardant layer 2 is provided with an insulation layer structure 3 for withstanding high voltage and isolating current to avoid leakage and breakdown. The insulation layer structure 3 is provided with seven strands of tin-plated copper wire 4 for transmitting electrical energy and ensuring stable current conduction. The insulation layer structure 3 is provided with a single strand of aramid fiber core 5 for preventing the copper wires from twisting and breaking.
[0020] As one implementation method in this embodiment, please refer to Figure 1 As shown, the seven tin-plated copper wires 4 and the single aramid fiber core 5 are in a concentric twisted structure. The diameter of the seven tin-plated copper wires 4 is 0.1-0.3 mm, and the diameter of the single aramid fiber core 5 is 0.1 mm.
[0021] Seven strands of tin-plated copper wire 4 with a diameter of 0.2mm and one strand of aramid fiber core 5 with a diameter of 0.1mm are selected and concentrically twisted using a special twisting equipment. During processing, the aramid fiber core 5 is first fixed on the central shaft of the twisting machine, and then the seven strands of tin-plated copper wire 4 are evenly distributed on the outside of the aramid fiber core 5. The twisting speed is controlled at 80-100r / min to ensure that the conductor structure after twisting is round and without looseness. The outer diameter of the conductor is controlled at 1.4-1.6mm to adapt to the subsequent coating processing of insulation layer, fire-retardant layer 2 and sheath layer, while meeting the current carrying capacity requirements of the charging pile cable.
[0022] As one implementation method in this embodiment, please refer to Figures 1-4As shown, the sheath layer structure 1 includes modified TPU 11, polycaprolactone 12 and nano silica 13. The mass percentage of polycaprolactone 12 is 10-15%, the mass percentage of nano silica 13 is 5%, and the overall thickness of the sheath layer structure 1 is 0.6-1mm.
[0023] According to the mass ratio of 80-85% modified TPU11, 10-15% polycaprolactone 12, and 5% nano silica 13, the three raw materials are put into a high-speed mixer and mixed at 80-90℃ for 15-20 minutes to ensure uniform mixing. Then, the mixed raw materials are fed into an extruder and extruded at a processing temperature of 180-200℃ to cover the outside of the fireproof and flame-retardant layer 2. By adjusting the extruder die parameters and traction speed, the overall thickness of the sheath layer structure 1 is controlled to be 0.8mm. Polycaprolactone 12 can improve the low-temperature flexibility of the sheath layer, so that the cable can still maintain good bending performance in a low-temperature environment of -40℃. Nano silica 13 enhances the wear resistance of the sheath layer and reduces the loss of the cable during dragging and friction.
[0024] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the sheath layer structure 1 also includes a spiral groove 14, the depth of which is 0.5-1mm and the pitch is 5-10mm.
[0025] During the extrusion molding process of the sheath layer, a raised structure matching the spiral groove 14 is set on the inner wall of the extruder die. When the sheath layer raw material is extruded from the die, the spiral groove 14 is naturally formed on its inner wall. During processing, the groove depth is controlled to be 0.8mm and the pitch is 8mm. The setting of the spiral groove 14 can reduce the contact area between the sheath layer and the fire-retardant layer 2, reduce the frictional resistance between the two layers when the cable is bent, improve the bending follow-up of the cable, and prevent the sheath layer from cracking due to stretching. At the same time, the channel formed by the spiral groove 14 can assist in heat dissipation when the cable transmits a large current, reduce the temperature rise of the cable, and ensure the long-term stable operation of the cable.
[0026] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the fireproof and flame-retardant layer 2 includes a glass fiber-basalt fiber mixed woven tape 21 and a halogen-free low-smoke flame-retardant tape 22. The glass fiber-basalt fiber mixed woven tape 21 has a mixing ratio of glass fiber to basalt fiber of 3:7, and the diameter of the single filament of the fiber used in the woven tape is 8-10μm. The overall thickness of the fireproof and flame-retardant layer 2 is 0.4-0.6mm.
[0027] First, the halogen-free low-smoke flame-retardant tape 22 is wrapped around the outside of the insulation layer structure 3 with a 50% overlap rate. During wrapping, the wrapping tension is controlled at 5-8N to ensure that the flame-retardant tape is tightly attached to the insulation layer without wrinkles. Then, glass fiber and basalt fiber are mixed in a 3:7 ratio to make yarn. The yarn is then woven onto the outside of the halogen-free low-smoke flame-retardant tape 22 using a braiding machine. During weaving, the weaving density is controlled at ≥90%, and the single filament diameter is selected as 9μm. Finally, a fireproof and flame-retardant layer 2 with an overall thickness of 0.5mm is formed. The halogen-free low-smoke flame-retardant tape 22 can release inert gas to suppress the flame when burning, while the glass fiber-basalt fiber mixed braided tape 21 can block the spread of the flame. The combination of the two enables the cable to meet the Class A fire protection requirements specified in GB / T19666-2019, and there is no release of toxic gases during combustion, with a smoke density ≤50%.
[0028] As one implementation method in this embodiment, please refer to Figures 1-4 As shown, the insulation layer structure 3 includes a thermoplastic elastomer 31 and a cross-linked polyethylene 32. The thickness of the thermoplastic elastomer 31 layer is 0.4-0.6 mm, and the thickness of the cross-linked polyethylene 32 layer is 0.8-1 mm.
[0029] The insulation layer structure 3 is processed using a double-layer co-extrusion process. First, cross-linked polyethylene 32 raw material with 3-5% nano-alumina particles is fed into the first extruder and extruded to coat the outside of the conductor at a temperature of 160-180℃. The thickness of the cross-linked polyethylene 32 layer is controlled at 0.9mm. The nano-alumina particles can inhibit the aging of cross-linked polyethylene 32 under high voltage and improve the voltage resistance of the insulation layer. Then, thermoplastic elastomer 31 raw material is fed into the second extruder and extruded to coat the outside of the cross-linked polyethylene 32 layer at a temperature of 170-190℃. The thickness of the thermoplastic elastomer 31 layer is controlled at 0.5mm. The Shore A hardness of thermoplastic elastomer 31 is 65, which can improve the flexibility of the insulation layer and adapt to the bending characteristics of the conductor. The co-extrusion molding of the two layers can ensure a tight bond and avoid delamination. The overall breakdown field strength of the insulation layer is ≥25kV / mm, which meets the high-voltage power supply requirements of the charging pile.
[0030] Working Principle: During use, this new energy high-flexibility, pressure-resistant, fire-resistant charging pile cable utilizes a conductor structure composed of seven strands of tin-plated copper wire 4 and one strand of aramid fiber core 5 to transmit electrical energy. The aramid fiber core 5 ensures the conductor is not easily broken during frequent bending. The cross-linked polyethylene 32 layers in the insulation layer structure 3 withstand high voltage and isolate current, while the thermoplastic elastomer 31 layers enhance the flexibility of the insulation layer. The fire-retardant layer 2, through the synergistic effect of halogen-free low-smoke flame-retardant tape 22 and glass fiber-basalt fiber braided tape 21, blocks the spread of flames and inhibits the release of toxic gases. The sheath layer structure 1 not only achieves wear resistance and low-temperature resistance through the combination of modified TPU 11, polycaprolactone 12, and nano-silica 13, but its inner wall spiral grooves 14 also reduce bending friction and assist in heat dissipation. The various layers work together to give the cable high flexibility, pressure resistance, and fire resistance, adapting to the usage scenarios of charging piles.
[0031] The above embodiments are only used to illustrate the technical solution of this utility model, and are not intended to limit it.
Claims
1. A new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable, characterized in that: The structure includes a sheath layer structure (1), the inner wall of which is fitted with a fire-retardant layer (2) for blocking the spread of flames and inhibiting the release of toxic gases to achieve fire safety protection, the inner wall of which is fitted with an insulating layer structure (3) for withstanding high voltage and isolating current to avoid leakage and breakdown, the interior of which is fitted with seven strands of tin-plated copper wire (4) for transmitting electrical energy and ensuring stable current conduction, and the interior of which is fitted with a strand of aramid fiber core (5) for preventing the copper wire from twisting and breaking.
2. The new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable according to claim 1, characterized in that: The seven strands of tin-plated copper wire (4) and the one strand of aramid fiber core (5) are in a concentric twisted structure. The diameter of the seven strands of tin-plated copper wire (4) is 0.1-0.3 mm, and the diameter of the one strand of aramid fiber core (5) is 0.1 mm.
3. The new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable according to claim 1, characterized in that: The sheath layer structure (1) includes modified TPU (11), polycaprolactone (12) and nano silica (13), and the overall thickness of the sheath layer structure (1) is 0.6-1 mm.
4. The new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable according to claim 1, characterized in that: The sheath layer structure (1) further includes a spiral groove (14), the depth of which is 0.5-1mm and the pitch is 5-10mm.
5. The new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable according to claim 1, characterized in that: The fireproof and flame-retardant layer (2) includes a glass fiber-basalt fiber mixed woven tape (21) and a halogen-free low-smoke flame-retardant tape (22). The glass fiber-basalt fiber mixed woven tape (21) has a mixing ratio of glass fiber to basalt fiber of 3:7, and the diameter of the single filament of the fiber used in the woven tape is 8-10μm. The overall thickness of the fireproof and flame-retardant layer (2) is 0.4-0.6mm.
6. The new energy high-flexibility, voltage-resistant, fire-resistant charging pile cable according to claim 1, characterized in that: The insulating layer structure (3) includes a thermoplastic elastomer (31) and a cross-linked polyethylene (32), wherein the thickness of the thermoplastic elastomer (31) layer is 0.4-0.6 mm and the thickness of the cross-linked polyethylene (32) layer is 0.8-1 mm.