Analysis of the technological breakthroughs and advantages of high-power automotive DC charging cables

Product Overview: At a time when electric vehicles are booming, high-power automotive DC charging cables, as core components of fast charging technology, are undergoing significant technological changes. Its technological breakthroughs have brought many practical advantages to electric vehicle users. The following are the ways and methods of cable manufacturers to break through innovation, for reference only. Please contact us for specific product details.

Technological breakthroughs, material innovation:

In terms of insulating materials, traditional materials are difficult to meet high power requirements, and new high-performance insulating materials are emerging. For example, some cables use specially formulated thermoplastic elastomers (TPE), which can stably maintain good insulation performance in a wide temperature range of -40℃ to 105℃, and can withstand a rated voltage of up to DC 1000V, effectively ensuring electrical safety during charging and preventing current leakage and short circuit risks.

Conductor materials have also made progress. Some manufacturers use high-purity bare copper as conductors. By optimizing the smelting process of copper materials and reducing the impurity content, they significantly improve conductivity, reduce resistance, and reduce the loss of electricity during transmission.

Innovation in heat dissipation technology: High-power charging generates a lot of heat, and heat dissipation becomes the key. Liquid cooling technology came into being. A circulating liquid cooling system is built inside the cable. The coolant flows in a closed pipe, efficiently taking away the heat generated during the charging process, so that the cable always maintains a suitable working temperature. For example, a certain brand of liquid-cooled cable can stably control the operating temperature below 60°C, ensuring the continuous and stable operation of high-power charging and avoiding the decrease in charging efficiency or safety hazards caused by overheating.

Advantages: High-power transmission guarantee With large-section conductors and advanced insulation design, high-power automotive DC charging cables have strong power transmission capabilities. For example, some advanced products can support charging powers of up to 500kW or even higher, which can inject a large amount of electrical energy into electric vehicle batteries in a short time, greatly shorten the charging time, greatly improve the energy replenishment efficiency of electric vehicles, and approach the convenient experience of refueling fuel vehicles, effectively alleviating users' mileage anxiety.

Low energy loss: Large-section conductors reduce current density and reduce resistance loss. At the same time, the optimization of heat dissipation technology further reduces the additional energy loss caused by heat, and significantly improves energy transmission efficiency. For example, the energy transmission efficiency of some high-quality cables can reach more than 95%, which means that under the same charging demand, it can reduce energy waste and reduce the user's charging cost. At the same time, it also improves energy utilization efficiency, which is in line with the development concept of energy conservation and environmental protection.

Improved safety performance: Liquid cooling technology not only solves the heat dissipation problem, but also indirectly improves safety. Stable operating temperature reduces the risk of safety accidents such as fire caused by overheating of the cable. In addition, the cable is usually designed with multiple safety protection mechanisms, such as overcurrent protection, short-circuit protection, etc., to ensure the safety and reliability of the charging process from multiple dimensions, providing solid protection for users.

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