CN109326375B - 柔性超a类铝合金芯新能源汽车用车内高压电缆 - Google Patents
柔性超a类铝合金芯新能源汽车用车内高压电缆 Download PDFInfo
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Abstract
本发明涉及电缆技术领域，具体涉及一种柔性超A类铝合金芯新能源汽车用车内高压电缆，其包括铝合金导体，以及依次包裹在铝合金导体外部的第一绕包隔离纸层、抗拉撕硅橡胶绝缘层、铝塑复合带屏蔽层、镀锡铜丝编织层、第二绕包隔离纸层、陶瓷化硅橡胶内护套和外护套，外护套8为玻纤纱层+硅碳复合材料涂层；本发明的高压电缆，其柔性好、屏蔽性能好且环保无毒，且耐火性能优良。
Description
技术领域
本发明涉及电缆技术领域，具体涉及一种柔性超A类铝合金芯新能源汽车用车内高压电缆。
背景技术
随着新能源汽车的快速发展，新能源车内高压电缆需求也越来越大，传统的低烟无卤阻燃交联聚烯烃绝缘车内高压电缆在柔软度，阻燃性能上不是十分理想。由于电动汽车连接装置，空间有限，对线缆的弯曲半径要求较高，这就要求电缆的柔软度要好。传统的低烟无卤阻燃交联聚烯烃绝缘车内高压电缆已不能满足客户的使用需求，在客户安装现场，往往因线缆太硬，不易弯曲，在整车组装过程中影响生产效率，甚至无法安装。
综上所述，开发柔性超A类铝合金芯新能源汽车用车内高压电缆，兼具柔性、高阻燃、高载流量轻量化功能，性价比突出，将具有广阔市场前景。
发明内容
本发明的目的在于克服现有技术的缺陷，提供一种柔性超A类铝合金芯新能源汽车用车内高压电缆，其柔性好、屏蔽性能好且环保无毒，且耐火性能优良。
为实现上述目的，本发明采用了如下技术方案：
一种柔性超A类铝合金芯新能源汽车用车内高压电缆，其包括铝合金导体1，以及依次包裹在铝合金导体1外部的第一绕包隔离纸层2、抗拉撕硅橡胶绝缘层3、铝塑复合带屏蔽层4、镀锡铜丝编织层5、第二绕包隔离纸层6、陶瓷化硅橡胶内护套7和外护套8，外护套8为玻纤纱层+硅碳复合材料涂层。
优选的，所述铝合金导体1由多根直径0.3～0.4mm铝合金丝，经分层紧压绞合而成，束丝方向和复绞方向均为左向。
优选的，所述第二绕包隔离纸层6由隔离纸单层重叠绕包在镀锡铜丝编织层5外部而成。
优选的，所述第一绕包隔离纸层2、铝塑复合带屏蔽层4和第二绕包隔离纸层6的绕包方向均为左向。
优选的，所述抗拉撕硅橡胶绝缘层3为邵氏45A抗拉撕硅橡胶绝缘层，陶瓷化硅橡胶内护套7为邵氏45A抗拉撕硅橡胶内护套。
优选的，所述铝塑复合带屏蔽层4由0.05mm厚的铝塑带绕包在抗拉撕硅橡胶绝缘层3外部而成。
优选的，每层的绞合截距为铝合金丝直径的4-10倍，铝合金导体1由三层构成，铝合金丝由以下重量份的原料组成：硅0.04～0.06份、铁0.25～0.4份、铜0.25～0.28份、镁0.06～0.15份、锆0.1～0.3份、锌0.01～0.03份、硼0.01～0.02份、铂0.02～0.04份、钛0.01～0.09份、钨0.02～0.03份、锰0.03～0.04份，其余为铝。
优选的，所述外护套8由包裹在陶瓷化硅橡胶内护套7外侧的玻纤纱编织层以及涂覆在玻纤纱编织层上的硅碳复合材料涂层构成，玻纤纱编织层为多孔结构，硅碳复合材料覆盖玻纤纱编织层表面并填满玻纤纱编织层的孔隙。
优选的，所述硅碳复合材料包括以下成分：乙烯基橡胶、炭微粉、二氧化硅微米粉、羟基硅油、瓷化粉、合成云母粉和交联剂。
优选的，所述硅碳复合材料的制备方法如下：将乙烯基橡胶、二氧化硅微米粉、瓷化粉、合成云母粉加入带有冷却设备的捏合机中，在70℃温度下处理2-3小时，使上述多个成分捏合搅拌均匀；再将纳米级炭微粉、羟基硅油和交联剂加入上述混合物，在加压条件下，捏和处理1-3小时，得到液体的硅碳复合材料。
本发明柔性超A类铝合金芯新能源汽车用车内高压电缆，其铝合金导体1导电性好且自重轻，有利于减轻新能源汽车的自重，提升新能源汽车的续航能力；其第一隔离纸层2将铝合金导体1与抗拉撕硅橡胶绝缘层3分离，避免在剥线时，铝合金导体1与抗拉撕硅橡胶绝缘层3发生黏连；其铝塑复合带屏蔽层4和镀锡铜丝编织层5形成双屏蔽结构，显著提高了电缆对高、低频信号全频段的抗干扰能力，提高了电缆的屏蔽性能；其陶瓷化硅橡内护套7有利于提高电缆的载流量，而且保证电缆的高阻燃性，其外护套8为玻纤纱+硅碳复合材料涂层，显著提高本发明电缆的机械性能同时不影响其柔软度，也使本发明电缆的防火性能得到进一步提升，尤其是玻纤纱和硅碳两种材料均具有优良的防火性能，且二者的复合材料也进一步提高了外护套8和陶瓷化硅橡胶内护套7之间良好的粘合。
附图说明
图1是本发明柔性超A类铝合金芯新能源汽车用车内高压电缆的结构示意图。
具体实施方式
以下结合附图1给出的实施例，进一步说明本发明的柔性超A类铝合金芯新能源汽车用车内高压电缆的具体实施方式。本发明的柔性超A类铝合金芯新能源汽车用车内高压电缆不限于以下实施例的描述。
本发明的柔性超A类铝合金芯新能源汽车用车内高压电缆，其包括铝合金导体1，以及依次包裹在铝合金导体1外部的第一绕包隔离纸层2、抗拉撕硅橡胶绝缘层3、铝塑复合带屏蔽层4、镀锡铜丝编织层5、第二绕包隔离纸层6、陶瓷化硅橡胶内护套7和外护套8，外护套8为玻纤纱+硅碳复合材料涂层。
本发明柔性超A类铝合金芯新能源汽车用车内高压电缆，其铝合金导体1导电性好且自重轻，有利于减轻新能源汽车的自重，提升新能源汽车的续航能力；其第一隔离纸层2将铝合金导体1与抗拉撕硅橡胶绝缘层3分离，避免在剥线时，铝合金导体1与抗拉撕硅橡胶绝缘层3发生黏连；其铝塑复合带屏蔽层4和镀锡铜丝编织层5形成双屏蔽结构，显著提高了电缆对高、低频信号全频段的抗干扰能力，提高了电缆的屏蔽性能；其陶瓷化硅橡内护套7有利于提高电缆的载流量，而且保证电缆的高阻燃性；其外护套8为玻纤纱编织层+硅碳复合材料涂层，显著提高本发明电缆的机械性能同时不影响其柔软度，也使本发明电缆的防火性能得到进一步提升，尤其是玻纤纱和硅碳两种材料均具有优良的防火性能，且二者的复合材料也进一步提高了外护套8和陶瓷化硅橡胶内护套7之间良好的粘合。
以下将结合说明书附图和具体实施例对本发明柔性超A类铝合金芯新能源汽车用车内高压电缆作进一步说明。
如图1所示，本发明柔性超A类铝合金芯新能源汽车用车内高压电缆包括铝合金导体1，以及依次包裹在铝合金导体1外部的第一绕包隔离纸层2、抗拉撕硅橡胶绝缘层3、铝塑复合带屏蔽层4、镀锡铜丝编织屏蔽层5、第二绕包隔离纸层6、陶瓷化硅橡胶内护套7和抗拉撕硅橡胶外护套8。
优选的，所述铝合金导体1由直径0.3～0.4mm铝合金丝，经分层紧压绞合而成。进一步的优选方案，每层的绞合截距为铝合金丝直径的4-10倍，铝合金导体1由三层构成。更进一步的，铝合金丝由以下重量份的原料组成：硅0.04～0.06份、铁0.25～0.4份、铜0.25～0.28份、镁0.06～0.15份、锆0.1～0.3份、锌0.01～0.03份、硼0.01～0.02份、铂0.02～0.04份、钛0.01～0.09份、钨0.02～0.03份、锰0.03～0.04份，其余为铝。
需要指出的是，上述构成的铝合金丝，铝和锆形成三铝化锆化合物，有利于细化铝合金中的晶粒，硅和镁反应形成的化合物，则显著提高了铝合金丝的强度，而铂则使铝合金丝的电阻率显著降低，使本发明的铝合金丝具有质量轻、强度高和电阻率低的优良特性。优选的，所述铝塑复合带屏蔽层4由0.05mm的铝塑带绕包在抗拉撕硅橡胶绝缘层3外部而成。
优选的，所述抗拉撕硅橡胶绝缘层3和抗拉撕硅橡胶外护套8，均由通过铂金体系硫化的邵氏45A抗拉撕硅橡胶构成，环保、无毒且无味。
优选的，所述铝合金导体1的束丝方向和复绞方向、第一绕包隔离纸2的绕包方向、第二绕包隔离纸层6的绕包方向、铝塑复合带屏蔽层4的绕包方向均为左向，避免电缆弯曲产生反向应力，有利于提高电缆的柔性。
所述的外护套8为玻纤纱编织层+硅碳复合材料涂层，显著提高本发明电缆的机械性能同时不影响其柔软度，也使本发明电缆的防火性能得到进一步提升，尤其是玻纤纱和硅碳两种材料均具有优良的防火性能，经实验证明，如果直接将硅碳复合材料涂覆在陶瓷化硅橡胶内护套7上，一则附着性不好，二来会增加电缆的硬度，而本发明的玻纤纱编织层为硅碳复合材料提供了优良的载体，使得硅碳复合材料可以很好的附着在玻纤纱编织层上，保持了硅碳复合材料的稳定性，不会从电缆上脱离，还保证了本发明电缆的柔性，进一步的，硅碳复合材料不仅涂覆于玻纤纱编织层表面，而且填满玻纤纱编织层的孔隙，避免发生火灾时，火焰或高温直接接触内护套17，大大的提升了本发明电缆的防火、耐火性能。所述的玻纤纱防止层+硅碳复合材料涂层的特性和制备方法如下：
1、玻纤纱为玻纤与聚酯聚合材料混合加工而成，硅炭复合材料为包含二氧化硅与炭黑材料的复合而成的防火型材料。
2、二者结合一是：减轻电缆重量，二是：编织成使用玻纤纱保持电缆的柔软，三是：涂覆硅炭复合防火材料电缆耐磨和防火有极大改善。
3、玻纤纱利用编织机编织在电缆外表面，编织好后的电缆，利用静涂工艺涂覆硅炭复合材料。
优选的，所述外护套8的另一种制备方法为，将玻纤纱纤维先制成玻纤纱材质的玻纤纱线，然后在玻纤纱线外涂覆硅碳复合材料(或者将玻纤纱线浸泡在硅碳复合材料的液体中)，形成外包有硅碳复合材料的玻纤纱纤线，然后由外包有硅碳复合材料的玻纤纱线编织为外护套8。
优选的，所述硅碳复合材料包括以下成分：乙烯基橡胶、炭微粉(纳米级)、二氧化硅微米粉、羟基硅油、瓷化粉、合成云母粉和交联剂。
优选的，所述硅碳复合材料的制备方法如下：将乙烯基橡胶、二氧化硅微米粉、瓷化粉、合成云母粉加入带有冷却设备的捏合机中，在70℃温度下处理2-3小时，使上述多个成分捏合搅拌均匀；再将炭微粉(纳米级)、羟基硅油和交联剂加入上述混合物，在a个大气压条件下，捏和处理1-3小时，得到液体的硅碳复合材料。
优选的，1<a≤10。
需要指出的是，所述硅碳复合材料也可以通过购买获得。
进一步优选的实施例二，本发明的柔性超A类铝合金芯新能源汽车用车内高压电缆，其包括铝合金导体1，以及依次包裹在铝合金导体1外部的石墨烯导电薄膜层、第一绕包隔离纸层2、抗拉撕硅橡胶绝缘层3、铝塑复合带屏蔽层4、镀锡铜丝编织层5、第二绕包隔离纸层6、陶瓷化硅橡胶内护套7和外护套8，外护套8为玻纤纱编织层+硅碳复合材料涂层。
在铝合金导体1外还设有石墨烯导电薄膜层，其石墨烯导电薄膜层不仅具有导电性能、非常高的强度和韧度，而且石墨烯导电薄膜层还具有良好的电子屏蔽和电磁波吸收特性，可以填补屏蔽层的间隙，可显著提高电缆抗电磁干扰的能力。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干简单推演或替换，都应当视为属于本发明的保护范围。
Claims (9)
1.一种柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于，其包括铝合金导体(1)，以及依次包裹在铝合金导体(1)外部的第一绕包隔离纸层(2)、抗拉撕硅橡胶绝缘层(3)、铝塑复合带屏蔽层(4)、镀锡铜丝编织层(5)、第二绕包隔离纸层(6)、陶瓷化硅橡胶内护套(7)和外护套(8)，外护套(8)为玻纤纱层+硅碳复合材料涂层；所述硅碳复合材料的原料包括以下成分：乙烯基橡胶、炭微粉、二氧化硅微米粉、羟基硅油、瓷化粉、合成云母粉和交联剂。
2.根据权利要求1所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述铝合金导体(1)由多根直径0.3～0.4mm铝合金丝，经分层紧压绞合而成，束丝方向和复绞方向均为左向。
3.根据权利要求1所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述第二绕包隔离纸层(6)由隔离纸单层重叠绕包在镀锡铜丝编织层(5)外部而成。
4.根据权利要求1或2所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述第一绕包隔离纸层(2)、铝塑复合带屏蔽层(4)和第二绕包隔离纸层(6)的绕包方向均为左向。
5.根据权利要求1所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述抗拉撕硅橡胶绝缘层(3)为邵氏45A抗拉撕硅橡胶绝缘层，陶瓷化硅橡胶内护套(7)为邵氏45A抗拉撕硅橡胶内护套。
6.根据权利要求1所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述铝塑复合带屏蔽层(4)由0.05mm厚的铝塑带绕包在抗拉撕硅橡胶绝缘层(3)外部而成。
7.根据权利要求2所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：每层的绞合截距为铝合金丝直径的4-10倍，铝合金导体(1)由三层构成，铝合金丝由以下重量份的原料组成：硅0.04～0.06份、铁0.25～0.4份、铜0.25～0.28份、镁0.06～0.15份、锆0.1～0.3份、锌0.01～0.03份、硼0.01～0.02份、铂0.02～0.04份、钛0.01～0.09份、钨0.02～0.03份、锰0.03～0.04份，其余为铝。
8.根据权利要求1所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述外护套(8)由包裹在陶瓷化硅橡胶内护套(7)外侧的玻纤纱编织层以及涂覆在玻纤纱编织层上的硅碳复合材料涂层构成，玻纤纱编织层为多孔结构，硅碳复合材料覆盖玻纤纱编织层表面并填满玻纤纱编织层的孔隙。
9.根据权利要求8所述的柔性超A类铝合金芯新能源汽车用车内高压电缆，其特征在于：所述硅碳复合材料的制备方法如下：将乙烯基橡胶、二氧化硅微米粉、瓷化粉、合成云母粉加入捏合机中，在70℃温度下处理2-3小时，使上述多个成分捏合搅拌均匀；再将纳米级炭微粉、羟基硅油和交联剂加入上述混合物，在加压条件下，捏和处理1-3小时，得到液体的硅碳复合材料。
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