Composition and production process of electric vehicle charging cables

With the popularity of electric vehicles and the increase in demand, the construction of charging facilities has become more and more important. As an important part of connecting electric vehicles and charging piles, the composition and production process of charging cables play a key role in their quality and safety.

I. Composition of electric vehicle charging cable

1. Outer sheath layer: the outer sheath layer is the outer protective layer of the charging cable, usually made of wear-resistant, high-temperature, cold-resistant and other characteristics of the material, in order to protect the internal conductor and the insulation layer from the effects of the external environment. At present, the more mainstream is TPU, TPE, PVC elastomer, etc.

2. Insulation layer: the insulation layer is an important part of the charging cable, used to isolate the conductor and the outer sheath layer, to prevent current leakage and short-circuit and other safety issues. Common insulating materials include polyethylene (PE), cross-linked polyethylene (XLPE) and so on.

3. Conductor: The conductor is the part of the charging cable responsible for the transmission of electrical energy, usually made of copper or aluminium and other materials with good electrical conductivity. The larger the cross-sectional area of the conductor, the greater the ability to transmit current.

4. Banding: The banding is the inner protective layer of the charging cable and is used to protect the conductor and filler from damage and external interference, making the cable stronger.

II. Production process of electric vehicle charging cable

Material preparation: according to the design requirements, prepare the required conductor, insulation materials, shielding materials, sheath materials and so on.

Conductor manufacturing: copper or aluminium materials according to the design requirements for drawing, stranding and other processes, made to meet the specifications of the conductor.

Insulation layer manufacturing: the insulating material for extrusion or coating process, the conductor will be wrapped in the insulating layer, forming an insulated conductor.

Shielding layer manufacturing: the shielding material for extrusion or coating process, the insulating conductor wrapped in the shielding layer to form a shielded insulated conductor.

Assembly and braiding: The shielded insulated conductors are assembled with other components, while processes such as braiding or braiding sleeves are performed to enhance the mechanical strength and abrasion resistance of the cable.

Outer sheath manufacturing: extruding or coating the outer sheath material, wrapping the assembled cable in the outer sheath to form the final charging cable.

Inspection and testing: conduct appearance inspection, electrical performance test, voltage resistance test, etc. on the produced charging cables to ensure that their quality and safety meet the standard requirements.

Packing and factory: Pack the qualified charging cables, mark the relevant information, and carry out factory inspection and record.

Through the above introduction of composition and production process, readers can have a better understanding of the composition and manufacturing process of electric vehicle charging cables. When selecting and using charging cables, attention should be paid to their quality and safety, and relevant standards and regulations should be followed to ensure the stability and safety of the charging process.