Cable for active cooling system for ultra-fast charging of electric vehicle

Abstract

A charging cable according to several embodiments of the present disclosure is disclosed. The charging cable comprises: a plurality of power supply units for supplying power to an electric vehicle; at least one recovery unit for recovering a cooling fluid; and a cable sheath that encompasses the outside of the charging cable, wherein the power supply unit can include: a conductor unit including a composite stranded wire; a first insulation layer that encompasses the conductor unit; a second insulation layer that encompasses the first insulation layer while spaced apart therefrom; a first coolant passage including a fluid passage, which is formed by the first insulation layer and a plurality of wires forming the composite stranded wire; and a second coolant passage including a fluid passage, which is formed between the first insulation layer and the second insulation layer.

Description

Cable for electric vehicle ultra-fast charging active cooling system

[0001] The present disclosure relates to an electric vehicle charging cable with improved cooling efficiency.

[0002] Electric vehicles (EVs) are vehicles that primarily use battery power to drive an AC or DC motor. Recently, with environmental issues such as global warming and climate change raising the seriousness of carbon emissions, the distribution and support of electric vehicles are expanding to achieve carbon neutrality, leading to a corresponding increase in demand for electric vehicles.

[0003] Electric vehicles power their motors by charging their batteries, and as the batteries deplete, they must be recharged. Therefore, the availability of charging stations for these vehicles is increasing. In the past, charging a battery took approximately 4 to 9 hours. However, with the recent proliferation of rapid chargers, charging a battery takes approximately 4 to 9 hours with an AC charger and approximately 30 minutes with a DC rapid charger.

[0004] Since a safety accident can occur if an electric vehicle's battery runs out while driving on the road, ultra-fast chargers that can rapidly charge large amounts of electricity are being installed in places where rapid charging is required, such as highways.

[0005] However, ultra-fast chargers supply large amounts of current in a short period of time for rapid charging, which can cause the charging cable that supplies power to the electric vehicle to overheat. This can damage the charging cable, reducing charging performance and posing a risk of fire.

[0006] Typically, a charging cable for a rapid charger for electric vehicles can be used at 100 kW with a safety allowable current of approximately 100 A in a DC 1000 V rated power system without a cooling device. If a cooling device is used in the same charging cable, the charging cable for electric vehicles can be used at 500 kW with a safety allowable current of approximately 500 A in a DC 1000 V rated power system. In other words, a higher cooling device efficiency for the same product can increase the rated capacity of the charging cable. Alternatively, increasing the rated capacity by increasing the conductor cross-sectional area and thus the allowable current can be considered, but this increases the cable diameter.

[0007] Therefore, there is a demand for an electric vehicle charging cable that efficiently cools the heat inside the charging cable when rapidly charging a large amount of power to an electric vehicle, reduces the conductor resistance of the cable, minimizes the outer diameter, and improves charging performance.

[0008] The present disclosure has been made in response to the aforementioned background technology, and provides a charging cable for an electric vehicle that efficiently cools the heat inside the cable generated during charging by allowing a cooling fluid to flow using a first refrigerant passage and a second refrigerant passage formed inside the charging cable during large-capacity rapid charging of an electric vehicle, thereby preventing an increase in the conductor resistance of the cable and enabling continuous charging, thereby efficiently cooling the heat inside the cable without increasing the conductor cross-sectional area, and minimizing the outer diameter by reducing the conductor resistance of the cable to improve charging performance.

[0009] The technical problems of the present disclosure are not limited to the technical problems mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art from the description below.

[0010] In order to solve the problem as described above, a charging cable comprising: a plurality of power units for supplying power; at least one recovery unit for recovering a cooling fluid; and a cable sheath formed to wrap around the outside of the charging cable; wherein the power unit may include: a conductor unit including a composite stranded wire; a first insulating layer wrapping the conductor unit; a second insulating layer spaced apart from the first insulating layer; a first refrigerant passage including a fluid passage formed by the first insulating layer and a plurality of strands forming the composite stranded wire; and a second refrigerant passage including a fluid passage formed between the first insulating layer and the second insulating layer.

[0011] Alternatively, the first insulating layer may be an insulating coating.

[0012] Alternatively, the insulating coating may be a fluororesin coating.

[0013] Alternatively, the first insulating layer may include pores formed to allow the cooling fluid to pass between the first refrigerant passage and the second refrigerant passage.

[0014] Alternatively, the first insulating layer may be a membrane taping that is permeable to the cooling fluid.

[0015] Alternatively, the first insulating layer may be a braided reinforcement layer.

[0016] Alternatively, the composite wire may be formed by at least one of a bundled wire formed by twisting a plurality of wires, a layered wire formed by twisting a plurality of wires in opposite directions between layers, or a uni-lay wire formed by twisting a plurality of wires in a uni-lay structure.

[0017] Alternatively, the charging cable may further include: a signal unit configured to perform signal exchange or communication within the cable sheath; and a grounding unit for grounding.

[0018] A method for assembling a charging cable for solving the above-described problem is disclosed. The method comprises: a step of manufacturing a grounding unit and a signal unit insulated from a conductor; a step of manufacturing an insulating tube of a power unit; a step of manufacturing an assembly combining the insulating tube of the power unit, the grounding unit, and the signal unit; a step of forming a cable sheath surrounding the assembly; a step of manufacturing a semi-finished product including a conductor unit of the power unit including a composite twisted wire and a first insulating layer of the power unit surrounding the conductor unit; a step of manufacturing a charging cable by inserting the semi-finished product into the insulating tube of the power unit, wherein the insulating tube of the power unit becomes a second insulating layer by inserting the semi-finished product; and

[0019] Step of assembling the above charging cable into the connector;

[0020] Including,

[0021] The above charging cable:

[0022] A first refrigerant passage including a fluid passage formed by the first insulating layer and a plurality of wires forming the composite wire; and

[0023] A second refrigerant passage including a fluid passage formed between the first insulating layer and the second insulating layer;

[0024] may include more.

[0025] The technical solutions obtainable in the present disclosure are not limited to the solutions mentioned above, and other solutions not mentioned will be clearly understood by a person having ordinary skill in the art to which the present disclosure pertains from the description below.

[0026] A charging cable for an electric vehicle according to some embodiments of the present disclosure can directly cool a conductor unit to enhance a cooling effect during large-capacity rapid charging of an electric vehicle.

[0027] In addition, the charging cable according to some embodiments of the present disclosure can prevent heat damage to the charging cable by reducing heat generation of the conductor with a cooling fluid, and can prevent safety accidents such as fire.

[0028] In addition, the charging cable according to some embodiments of the present disclosure can minimize the outer diameter of the charging cable by allowing the cooling fluid to flow through a space formed inside the power unit without a separate pipe for flowing the cooling fluid, thereby improving user convenience.

[0029] In addition, according to some embodiments of the present disclosure, a charging cable used in a rapid charger for an electric vehicle can be provided that efficiently cools the heat inside the cable by using a refrigerant passage formed inside the charging cable during large-capacity rapid charging of an electric vehicle, and improves charging performance while minimizing the outer diameter by reducing the conductor resistance of the cable.

[0030] The effects that can be obtained from the present disclosure are not limited to the effects mentioned above, and other effects that are not mentioned will be clearly understood by a person having ordinary skill in the art to which the present disclosure pertains from the description below.

[0031] Various aspects are now described with reference to the drawings, wherein like reference numerals are used to refer to similar components generally. In the following examples, for purposes of explanation, numerous specific details are set forth to provide a comprehensive understanding of one or more aspects. However, it will be apparent that such aspects may be practiced without these specific details.

[0032] FIG. 1 is an exemplary diagram of an electric vehicle large-capacity rapid charging system including a charging cable according to some embodiments of the present disclosure.

[0033] FIG. 2 is a schematic cross-sectional view of a charging cable according to some embodiments of the present disclosure.

[0034] Figure 3 is a drawing for explaining a conductor unit and a first insulating layer.

[0035] FIG. 4 is a drawing illustrating pores on an insulating coating according to some embodiments of the present disclosure.

[0036] FIG. 5 is a drawing illustrating membrane taping according to some embodiments of the present disclosure.

[0037] Figure 6 is a conceptual diagram for explaining a method of assembling a conventional charging cable.

[0038] FIG. 7 is a conceptual diagram illustrating a method of assembling a charging cable according to some embodiments of the present disclosure.

[0039] FIG. 8 is a flowchart of a method of assembling a charging cable according to some embodiments of the present disclosure.

[0040] Various embodiments and / or aspects are now disclosed with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of one or more aspects. However, it will be apparent to one skilled in the art that such aspects may be practiced without these specific details. The following description and the accompanying drawings detail specific exemplary aspects of one or more aspects. However, these aspects are exemplary, and any of the various methods within the principles of various aspects may be utilized, and the description is intended to encompass all such aspects and their equivalents. Specifically, the terms "embodiment," "example," "aspect," and "example" as used herein are not intended to imply that any aspect or design described therein is preferred or advantageous over other aspects or designs.

[0041] Hereinafter, regardless of the drawing numbers, identical or similar components are assigned the same reference numerals, and redundant descriptions thereof are omitted. Furthermore, when describing the embodiments disclosed in this specification, if a detailed description of a related known technology is judged to obscure the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted. Furthermore, the attached drawings are only intended to facilitate easy understanding of the embodiments disclosed in this specification, and the technical concepts disclosed in this specification are not limited by the attached drawings.

[0042] Although the terms "first" and "second" are used to describe various elements or components, these elements or components are not limited by these terms. These terms are merely used to distinguish one element or component from another. Therefore, it should be understood that a "first" element or component referred to below may also be a "second" element or component within the technical scope of the present invention.

[0043] Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used in their common sense to those of ordinary skill in the art to which the present invention pertains. Furthermore, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless explicitly and specifically defined otherwise.

[0044] Furthermore, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or." That is, unless otherwise specified or clear from context, "X employs A or B" is intended to mean either of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, "X employs A or B" can apply to any of these cases. Furthermore, the term "and / or" as used herein should be understood to refer to and include all possible combinations of one or more of the associated items listed.

[0045] Additionally, it should be understood that the terms "comprises" and / or "comprising" imply the presence of the features and / or components, but do not preclude the presence or addition of one or more other features, components and / or groups thereof.

[0046] Additionally, unless otherwise specified or clear from context to refer to the singular form, the singular in this specification and claims should generally be construed to mean “one or more.”

[0047] The purpose and effects of the present disclosure, as well as the technical configurations for achieving them, will become clearer with reference to the embodiments described below in detail, along with the accompanying drawings. In describing the present disclosure, detailed descriptions of known functions or configurations will be omitted if they are deemed to unnecessarily obscure the gist of the disclosure. Furthermore, the terms described below are defined based on the functions of the present disclosure and may vary depending on the intent or custom of the user or operator.

[0048] However, the present disclosure is not limited to the embodiments disclosed below and may be implemented in various other forms. These embodiments are provided solely to ensure the completeness of the disclosure and to fully inform those skilled in the art of the disclosure of the scope of the disclosure. The disclosure is defined solely by the scope of the claims. Therefore, such definitions should be based on the contents of this specification as a whole.

[0049] FIG. 1 is an exemplary drawing of an electric vehicle large-capacity rapid charging system including a charging cable (1000) according to some embodiments of the present disclosure.

[0050] Referring to Fig. 1, a large-capacity rapid charging system for an electric vehicle includes an electric vehicle (10) and a rapid charger (20). For large-capacity rapid charging of the electric vehicle (10), the rapid charger (20) is connected to the electric vehicle (10) via a cable connector (30) and a charging cable (1000).

[0051] The cable connector (30) is mounted on a charging connector (not shown) provided in an electric vehicle (10), and electricity can be supplied to the electric vehicle (10) through a charging cable (1000).

[0052] When rapidly charging a large amount of electricity to an electric vehicle (10), a large amount of current is supplied in a short period of time, which may generate heat in the charging cable (1000). This heat may damage the charging cable or cause a fire.

[0053] To solve these problems, according to an embodiment of the present disclosure, a charging cable (1000) is provided that improves performance by reducing conductor resistance while directly cooling a heat-generating conductor.

[0054] Hereinafter, the structure of the above-described charging cable (1000) will be specifically described with reference to FIGS. 2 to 5.

[0055] FIG. 2 is a schematic cross-sectional view of a charging cable (1000) according to some embodiments of the present disclosure. FIG. 3 is a drawing for explaining a conductor unit (110) and a first insulating layer (120). FIG. 4 is a drawing for explaining pores (121) on an insulating coating (120a) according to some embodiments of the present disclosure. FIG. 5 is a drawing for explaining membrane taping (120b) according to some embodiments of the present disclosure.

[0056] Referring to FIG. 2, the charging cable (1000) may include a power unit (100), a recovery unit (200), a grounding unit (300), a signal unit (400), and a cable sheath (500). The components illustrated in FIG. 1 are exemplary, and additional components may be present or some of the components may be omitted.

[0057] Below, a power unit (100) of a charging cable (1000) according to some embodiments of the present disclosure that are different from conventional charging cables (2000) is first described.

[0058] In some examples, the power unit (100) may be multiple. For example, as illustrated in FIG. 2, the power unit (100) may include a positive power unit and a negative power unit. The power unit may transmit power from the rapid charger (20) to the electric vehicle (10).

[0059] Specifically, the power unit (100) may include a conductor unit (110), a first insulating layer (120) surrounding the conductor unit (110), and a second insulating layer (130) surrounding the first insulating layer (120). In the case where the power unit (100) includes a positive power unit and a negative power unit, the positive power unit and the negative power unit are configured identically to each other, so for convenience, one power unit (110) will be described as an example below.

[0060] The conductor unit (110) may be formed of a composite stranded wire comprising a plurality of strands. For example, the conductor unit (110) may include a composite stranded wire formed by twisting a plurality of strands. Each strand may be a low-resistance annealed wire, but is not limited thereto.

[0061] For example, each strand may be formed by twisting 26 strands. Each strand may be formed of at least one material capable of conducting electricity, such as copper, iron, or aluminum, and may preferably be annealed copper wire.

[0062] Next, the composite wire may be formed of at least one of a bundled wire formed by twisting a plurality of wires, a layered wire formed by twisting a plurality of wires in opposite directions between layers, or a uni-lay wire formed by twisting a plurality of wires in a uni-lay structure.

[0063] In various embodiments, the number of each strand and each wire included in the composite strand is not limited to the description described above, and the number of each strand and each wire can be configured in various ways.

[0064] The first insulating layer (120) can surround the conductor unit (110). As illustrated in FIG. 3, a space formed by the first insulating layer (120) and the plurality of strands forming the composite strand can be used as a fluid passage. A refrigerant passage including a fluid passage formed by the first insulating layer and the plurality of strands forming the composite strand can be referred to as a first refrigerant passage (140). In other words, the first refrigerant passage (140) can mean a space (e.g., a gap between the plurality of strands forming the composite strand) through which a fluid can flow within a perimeter defined by the first insulating layer.

[0065] The second insulating layer (130) can surround the first insulating layer (120). For example, the second insulating layer (130) can surround the first insulating layer (120) while being spaced apart from the first insulating layer (120). In this case, the space spaced apart between the first insulating layer (130) and the second insulating layer can be used as a fluid passage. The space formed between the first insulating layer (120) and the second insulating layer (130) can be referred to as a second refrigerant passage (150). In other words, the second refrigerant passage (150) can mean a donut-shaped space formed between the first insulating layer (120) and the second insulating layer (130). In some examples, the second insulating layer (130) may be made of at least one material selected from the group consisting of polyethylene, polyurethane, fluororesin, polypropylene, rubber, polyvinyl chloride, thermoplastic elastomer, and thermoplastic polyurethane. However, the present invention is not limited thereto, and the second insulating layer (130) may be made of various materials.

[0066] In some examples, depending on the configuration of the first insulation layer (120), the charging cable (1000) can perform cooling operations according to various charging capacities using at least one of the first refrigerant passage (140) and the second refrigerant passage (150).

[0067] Specifically, the first insulating layer (120) may be an insulating coating (120a). FIG. 3 (a) illustrates a partial view of a power unit (100) in which an insulating coating (120a) surrounds a conductor unit (110) including a composite stranded wire (110a) formed by a plurality of fine wires. In addition, FIG. 3 (b) illustrates a partial view of a power unit (100) in which an insulating coating (120a) surrounds a conductor unit (110) including a composite stranded wire (110b) formed by twisting a plurality of fine wires in a uni-lay structure. The insulating coating (120a) may be a relatively hard coating layer formed by applying an insulating paint on the conductor unit (110) and then heating and baking it. In some examples, the insulating coating (120a) may be a fluororesin coating. However, the present invention is not limited thereto, and the insulating coating (120a) may include various coatings.

[0068] In some examples, the insulating coating (120a) may be formed as a relatively hard layer and thus may not be permeable to the cooling fluid. Accordingly, the insulating coating (120a) may be wrapped around the conductor unit (110) to separate the conductor unit (110) from the insulating material having a high insulation resistance, in order to prevent interference with the cooling circulation caused by foreign substances that may occur when the refrigerant is directly contacted with the conductor unit (110). By allowing the cooling fluid to pass through only the second refrigerant passage (140), the charging cable (1000) can be used as a 350 kW charging cable, for example.

[0069] As another example, the charging cable (1000) may pass cooling fluid through both the first refrigerant passage (140) and the second refrigerant passage (150) to increase cooling efficiency. In this case, the charging cable (1000) may be used as a 500 kW charging cable, for example.

[0070] In some examples, to further enhance cooling efficiency, the charging cable (1000) may include a configuration that circulates a cooling fluid between the first refrigerant passage (140) and the second refrigerant passage (150). For example, referring to FIG. 4, the first insulating layer (120), which is an insulating coating (120a), may include pores (121) formed to allow a cooling fluid to pass between the first refrigerant passage (140) and the second refrigerant passage (150). In this case, the cooling fluid flowing through the first refrigerant passage (140) may move to the second refrigerant passage (150) through the pores (121) of the insulating coating (120a). Conversely, the cooling fluid flowing through the second refrigerant passage (150) may move to the first refrigerant passage (140) through the pores (121) of the insulating coating (120a). As the refrigerant fluid circulates between the first refrigerant passage (140) and the second refrigerant passage (150) through the pores, heat generated in the conductor unit (110) can be efficiently transferred to the outside of the power unit (100). A charging cable (1000) having pores (121) on the insulating coating (120b) for circulating the refrigerant fluid between the first refrigerant passage (140) and the second refrigerant passage (150) through the pores (121) can be used as, for example, an 800 kW-class charging cable.

[0071] In some examples, the pores (121) may have a shape having a gradient that defines a circulation direction of the cooling fluid between the first refrigerant passage (140) and the second refrigerant passage (150). For example, the pores (121) of the first shape may have a shape that has an opening formed on the outside of the insulating coating (120a) at the front along the flow direction of the cooling fluid, and an opening formed on the inside of the insulating coating (120b) at the rear along the flow direction of the cooling fluid. In this case, the pores (121) may define a circulation direction that allows the cooling fluid of the second cooling passage (150) to enter through the opening formed on the outside of the insulating coating (120a) located at the front, and allows the cooling fluid to exit to the first cooling passage (140) through the opening formed on the inside of the insulating coating (120a) located at the rear.

[0072] As another example, the second shape pore (121) may have a shape in which an opening is formed on the inside of the insulating coating (120a) at the front along the direction of flow of the cooling fluid, and an opening is formed on the outside of the insulating coating (120b) at the rear along the direction of flow of the cooling fluid. In this case, the pore (121) may define a circulation direction in which the cooling fluid of the first cooling passage (140) is introduced through the opening formed on the inside of the insulating coating (120a) located at the front, and the cooling fluid is discharged to the second cooling passage (140) through the opening formed on the outside of the insulating coating (120a) located at the rear. In some examples, a plurality of pores (121) of the first shape and the second shape may be alternately arranged at regular intervals to circulate the cooling fluid in an intended circulation direction.

[0073] The charging cable (1000) may include another configuration for circulating a cooling fluid between the first refrigerant passage (140) and the second refrigerant passage (150) as the first insulation layer (120). For example, the first insulation layer (120) of the charging cable (1000) may be a membrane taping (120a) that is permeable to the cooling fluid. The membrane taping (120b) may have a membrane structure (i.e., a filtering membrane that selectively passes a desired substance) that is capable of not only general filtration that separates insoluble particles in a liquid or gaseous state, but also separation of dissolved substances or mixed gases dissolved in a liquid. FIG. 3 (a) illustrates a partial view of a power unit (100) in which a membrane taping (120b) wraps a conductor unit (110) including a composite stranded wire (110a) composed of a plurality of fine wires. In addition, (b) of FIG. 3 illustrates a partial view of a power unit (100) in which a membrane taping (120b) wraps a conductor unit (110) including a composite stranded wire (110b) formed by twisting a plurality of wires in a uni-lay structure. Referring to FIG. 5, the membrane taping (120b) may have a structure that wraps the conductor unit (110) in a taping manner. In this case, the cooling fluid flowing through the first refrigerant passage (140) can move to the second refrigerant passage (150) through the membrane taping (120b). Conversely, the cooling fluid flowing through the second refrigerant passage (150) can move to the first refrigerant passage (140) through the membrane taping (120b). As the refrigerant fluid circulates between the first refrigerant passage (140) and the second refrigerant passage (150) through the membrane taping (120b), heat generated on the conductor unit (110) can be efficiently transferred to the outside of the power unit (100). A charging cable using the membrane taping (120b) that circulates the refrigerant fluid between the first refrigerant passage (140) and the second refrigerant passage (150) can be used as, for example, an 800 kW-class charging cable.

[0074] In some examples, the first insulating layer (120) may be a braided reinforcement layer (120c). For example, the braided reinforcement layer (120c) may be formed to surround an outer surface of the conductor unit (110) by being disposed between the conductor unit (110) and the second insulating layer (130). FIG. 3 (a) illustrates a partial view of a power unit (100) in which a braided reinforcement layer (120c) surrounds a conductor unit (110) including a composite stranded wire (110a) formed of a plurality of fine wires. In addition, FIG. 3 (b) illustrates a partial view of a power unit (100) in which a braided reinforcement layer (120c) surrounds a conductor unit (110) including a composite stranded wire (110b) formed by twisting a plurality of thin wires into a uni-lay structure. In this case, the first insulation layer (120) composed of a braided reinforcement layer (120c) can perform the function of increasing the cross-sectional area through which the cooling fluid can pass by integrating the first refrigerant passage (140) and the second refrigerant passage (150). The braided reinforcement layer (120c) formed in this way can form a space in which the cooling fluid can flow between the conductor unit (110) and the second insulation layer (130) wider than in a conventional cable. Since a large amount of the cooling fluid flows from the rapid charger (20) toward the electric vehicle (10) through a wider space than in a conventional cable, the cooling efficiency of the charging cable (1000) can be increased.

[0075] The braided reinforcement layer (120c) may be formed by braiding a plurality of strands according to a preset braid density. The preset braid density may be a preset braid density to secure a space through which the cooling fluid can easily flow between the conductor unit (110) and the second insulating layer (130), but is not limited thereto.

[0076] Below, components of the charging cable (1000) other than the power unit (100) are described.

[0077] The recovery unit (200) is configured to recover the cooling fluid that has passed through the first refrigerant passage (140) and the second refrigerant passage (150) toward the rapid charger (20). Referring to FIG. 2, the recovery unit (200) may be disposed in contact with a pair of power units (100) and on the opposite side to the grounding unit (300). The cooling fluid flowing through the fluid passage may be supplied from the rapid charger (20) toward the electric vehicle (10) and recovered through the recovery unit (200) toward the rapid charger (20) again. For example, the recovery unit (200) may be made of a material such as nylon, polyethylene, polyurethane, polypropylene, fluororesin, rubber, polyvinyl chloride, thermoplastic elastomer, thermosetting flame-retardant or non-flame-retardant halogen-free polyolefin, thermoplastic polyurethane, PEEK, engineering plastic, etc.

[0078] The grounding unit (300) may include a plurality of grounding conductors (310) and an insulating layer (320) formed to surround the plurality of grounding conductors (310). For example, the grounding unit (300) may include seven grounding conductors (310). In addition, the insulating layer (320) may be made of a material such as rubber or plastic.

[0079] The signal unit (400) can exchange data for rapid charging with the rapid charger (20). In some examples, the signal unit (400) can include a signal line and an insulator surrounding the signal line. In FIG. 2, the charging cable (1000) is illustrated as including two signal units, but is not limited thereto. The signal line can transmit a signal for rapid charging and can be formed of a material such as a copper wire or an optical fiber. The insulator is configured to insulate the signal line and can be formed of a material such as a non-conductive polyethylene, polyurethane, polypropylene, fluororesin, rubber, polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), a thermosetting flame-retardant or flame-retardant halogen-free cross-linked polyolefin (HF-XLPO), or a thermoplastic polyurethane (TPU), PEEK, an engineering plastic, etc.

[0080] A cable sheath (500) can accommodate a plurality of power units (100), a recovery unit (200), a grounding unit (300), and a plurality of signal units (400) inside a charging cable (1000) and protect them from being exposed to the outside. For example, the cable sheath (500) can be formed of at least one material selected from the group consisting of polyethylene, polyurethane, PEEK, engineering plastic, polypropylene, fluororesin, rubber, polyvinyl chloride, thermoplastic elastomer, and thermoplastic polyurethane.

[0081] Fig. 6 is a drawing for explaining a conventional charging cable assembly method. Fig. 7 is a drawing for explaining a charging cable (1000) assembly method according to some embodiments of the present disclosure.

[0082] Referring to Fig. 6, according to a conventional method for manufacturing a charging cable, a process for manufacturing a conductor is first performed. Then, a process for manufacturing a power unit, a grounding unit, and a signal unit that insulate the conductor is performed. Then, a process for manufacturing a combination that combines the manufactured power unit, grounding unit, and signal unit is performed. Then, a process for manufacturing a charging cable is performed by wrapping an insulating covering around the outside of the combination. The manufactured charging cable can be assembled into a connector.

[0083] Referring to FIG. 7, according to a method for manufacturing a charging cable according to some embodiments of the present disclosure, a process of manufacturing a conductor and manufacturing a grounding unit (300) and a signal unit (400) that insulate the conductor may be performed in the same manner as in FIG. 6. However, the power unit (400) may be semi-manufactured by first manufacturing only the insulating tube without the conductor unit (110). Then, a process of manufacturing an assembly that connects the insulating tube of the power unit (100), the grounding unit (300), and the signal unit (400) may be performed. Then, a process of manufacturing a charging cable by wrapping a covering for insulation around the outside of the assembly may be performed. Separately, a process of manufacturing a semi-finished product including a conductor unit (110) of the power unit (100) including a composite twisted wire and a first insulating layer (120) of the power unit (100) that wraps the conductor unit (100) may be performed. In addition, a process of inserting a semi-finished product having a conductor unit (110) and a first insulating layer (120) surrounding the conductor unit (110) into an insulating tube of a power unit (400) included in the assembly can be performed. In this case, the insulating tube can become a second insulating layer (130) by inserting the semi-finished product.

[0084] Specifically, when a conductor unit (110) including a composite stranded wire is inserted into an insulating tube of a power unit (110) within a combination, problems such as wire bending and breakage of the constituent wires of the fine wires may occur. To prevent this, instead of inserting only the conductor unit (110) into the insulating tube, a semi-finished product having a conductor unit (110) and a first insulating layer (120) surrounding the conductor unit (110) is first produced, and then the semi-finished product is inserted into the insulating tube, thereby manufacturing the power unit (100). That is, the first insulating layer (120) performs the function of reinforcing the composite stranded wire by braiding, thereby preventing a bending phenomenon due to insertion into the insulating tube. In other words, a charging cable (1000) according to some embodiments of the present disclosure may be manufactured by inserting the conductor unit (110) into the insulating tube before being assembled into a connector. Here, the first insulating layer (120) is preferably a braided reinforcing layer. However, without being limited thereto, the first insulating layer (120) may be an insulating coating (120a) or membrane taping (120b).

[0085] FIG. 8 is a flowchart of a method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure.

[0086] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s100) of manufacturing a grounding unit (300) and a signal unit (400) that insulate a conductor.

[0087] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s200) of manufacturing an insulating tube of a power unit (100).

[0088] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s300) of manufacturing a combined body that combines an insulating tube of the power unit, the grounding unit (300), and a signal unit (400).

[0089] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s400) of forming a cable sheath (500) surrounding the assembly.

[0090] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s500) of manufacturing a semi-finished product including a conductor unit of the power unit including a composite twisted wire and a first insulating layer of the power unit wrapping the conductor unit.

[0091] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s600) of manufacturing the charging cable (1000) by inserting the semi-finished product into an insulating tube of the power unit (100).

[0092] A method for manufacturing a charging cable (1000) according to some embodiments of the present disclosure may include a step (s700) of assembling the charging cable (1000) into a connector.

[0093] The steps described above are presented for illustrative purposes only, and some steps may be omitted or additional steps may be added. Furthermore, the steps described above may be performed in any order.

[0094] The description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the scope of the present disclosure. Therefore, the present disclosure is not intended to be limited to the embodiments disclosed herein, but is to be construed in the broadest scope consistent with the principles and novel features disclosed herein.

[0095] The scope of rights for a method in the claims of this disclosure arises from the functions and features described in each step, and is not affected by the order in which the steps are described in the claims, unless the order of the steps constituting the method is explicitly stated. For example, in a claim describing a method including steps A and B, even if step A is described before step B, the scope of rights is not limited by the requirement that step A precede step B.

[0096] As described above, the relevant contents have been described in the best form for carrying out the invention.

[0097] The present disclosure can provide a cable for an electric vehicle ultra-fast charging active cooling system with improved cooling efficiency.

Claims

1. Regarding the charging cable, Multiple power units to supply power; At least one recovery unit for recovering cooling fluid; and A cable sheath formed to wrap around the outer side of the charging cable; Including, The above power unit: Conductor unit including composite conductor; A first insulating layer surrounding the above conductor unit; A second insulating layer surrounding the first insulating layer; A first refrigerant passage including a fluid passage formed by the first insulating layer and a plurality of wires forming the composite wire; and A second refrigerant passage including a fluid passage formed between the first insulating layer and the second insulating layer; Including, Charging cable.

2. In paragraph 1, The above first insulating layer is an insulating coating, Charging cable.

3. In paragraph 2, The above insulating coating is a fluororesin coating. Charging cable.

4. In paragraph 1, The first insulating layer includes pores formed to allow the cooling fluid to pass between the first refrigerant passage and the second refrigerant passage. Charging cable.

5. In paragraph 1, The above first insulating layer is a membrane taping that is permeable to the cooling fluid. Charging cable.

6. In paragraph 1, The above first insulating layer is a braided reinforcement layer, Charging cable.

7. In paragraph 1, The above composite wire is formed by at least one of a bundled wire formed by twisting multiple wires, a layered wire formed by twisting multiple wires in opposite directions between layers, or a uni-lay wire formed by twisting multiple wires in a uni-lay structure. Charging cable.

8. In paragraph 1, The above charging cable: A signal unit configured to perform signal exchange or communication within the above cable system; and Grounding unit for grounding; Including more, Charging cable.

9. How to assemble the charging cable: A step for manufacturing a grounding unit and a signal unit insulated from a conductor; Step for manufacturing an insulating tube of a power unit; A step of manufacturing a union combining the insulating tube of the power unit, the grounding unit and the signal unit; A step of forming a cable sheath surrounding the above-mentioned union; A step of manufacturing a semi-finished product including a conductor unit of the power unit including a composite wire and a first insulating layer of the power unit wrapping the conductor unit; A step of manufacturing a charging cable by inserting the semi-finished product into an insulating tube of the power unit, wherein the insulating tube of the power unit becomes a second insulating layer by inserting the semi-finished product; and Step of assembling the above charging cable into the connector; Including, The above charging cable: A first refrigerant passage including a fluid passage formed by the first insulating layer and a plurality of wires forming the composite wire; and A second refrigerant passage including a fluid passage formed between the first insulating layer and the second insulating layer; Including more, method.

10. In paragraph 9, The second insulating layer is an insulating coating, membrane taping, or braided reinforcement layer. method.

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