CN115691863A - Vibration-resistant high-voltage shielded cable and manufacturing method thereof - Google Patents

Abstract

The present disclosure provides a vibration-resistant high-voltage shielded cable and a method of manufacturing the same. The shielding cable comprises a conductor part, an insulating layer, a shielding layer and a sheath layer from inside to outside in sequence. The shielding layer includes a metal layer and a braid layer. Wherein, the metal layer is located between insulating layer and the weaving layer. The shielded cable provided by the present disclosure can reduce the possibility of stress fracture of the braid and increase the tensile properties and shielding properties of the shielded cable.

Description

Vibration-resistant high-voltage shielded cable and manufacturing method thereof

Technical Field

The present disclosure relates to the field of cables, and particularly to a cable with a shielding function.

Background

In new energy vehicles, no matter hybrid vehicles or pure electric vehicles, a high-voltage system is one of core components, and the importance of the high-voltage system is self-evident. The high-voltage wire harness is used as a medium for mutually associating all components in the high-voltage system, and plays an important role and influence on the safety of the new energy automobile. Therefore, it is an important requirement of a new energy automobile to improve the self-capability (for example, voltage resistance, current resistance, temperature resistance, shielding performance, etc.) of the high-voltage cable.

In addition to the above properties, due to the different locations and roles of the applications of the high voltage harness segments, other special requirements are created for the high voltage cable than the above conventional performance requirements. For example, high frequency vibrations generated during operation of the compressor and tension due to the vibrations may make the high voltage cable at this location more susceptible to failure due to the connection of the air conditioning compressor harness to the compressor. At present, a wire harness of an air conditioner compressor of a new energy automobile adopts a small-specification high-voltage shielding cable, and the problem of breakage of a conductor and a shielding layer of the cable is easily caused under the working conditions of high-frequency vibration and stretching, so that the service life of the cable is shortened.

Therefore, there is a need for improvements to existing high voltage shielded electrical cables to improve the performance of the high voltage shielded electrical cables.

Disclosure of Invention

The technical scheme provided by the invention aims to solve the problems that the performance of the shielded cable needs to be improved and/or the conductor and/or the shielding layer of the shielded cable are easy to break under the working conditions of high-frequency vibration and stretching in the prior art.

In one aspect of the present invention, there is provided a shielded cable including, in order from the inside to the outside: a conductor part; an insulating layer; a shield layer, the shield layer comprising: a metal layer; and a braid layer; and the metal layer is positioned between the insulating layer and the woven layer.

In at least one embodiment of one aspect of the present invention, the shielding layer further comprises a plastic layer, the metal layer is located between the plastic layer and the woven layer and is adjacent to the woven layer, wherein the metal layer and the plastic layer together form a composite layer.

In at least one embodiment of one aspect of the present invention, the metal layer is a first aluminum layer, and the composite layer further includes a second aluminum layer located between and immediately adjacent to the insulating layer and the plastic layer.

In at least one embodiment of one aspect of the present invention, the jacket layer is immediately adjacent to the braid layer.

In at least one embodiment of one aspect of the present invention, the conductor portion includes a copper wire.

In at least one embodiment of one aspect of the present invention, the conductor part further comprises at least one of a copper foil wire and a synthetic fiber, wherein the copper wire is twisted together with the at least one of the copper foil wire and the synthetic fiber, and the synthetic fiber comprises at least one of: aramid yarn, polyester yarn, or nylon yarn.

In at least one embodiment of one aspect of the present invention, the diameter of the copper wire is the same as the diameter of the copper foil wire.

In at least one embodiment of one aspect of the invention, the braid is braided from a tin-plated copper wire.

In at least one embodiment of one aspect of the present invention, the tinned copper wire is an electroplated tinned copper wire.

In another aspect of the present invention, there is provided a shielded cable manufacturing method including: step S203: coating an insulating layer outside the conductor part; step S205: covering a shielding layer outside the insulating layer, wherein the shielding layer comprises a metal layer and a braided layer, and after covering the shielding layer, the metal layer is positioned between the insulating layer and the braided layer; and step S207: and a sheath layer is coated outside the braided layer of the shielding layer.

In at least one embodiment of another aspect of the present invention, step S205 includes: step S205-1 and step S205-3 are performed simultaneously, wherein step S205-1 includes coating the metal layer outside the insulating layer, and step S205-3 includes coating the woven layer outside the metal layer.

In at least one embodiment of another aspect of the present invention, step S205-1 further comprises: and coating the metal layer outside the insulating layer by a longitudinal coating process.

In at least one embodiment of another aspect of the present invention, step S205-3 further comprises: and weaving the electroplating tinned copper wire on the outer surface of the metal layer through a precise weaving process.

In at least one embodiment of another aspect of the present invention, the method further comprises: step S201: twisting at least one of a copper foil wire and an aramid wire together with the copper wire to form the conductor part.

Compared with the prior art, the invention can have one or more of the following advantages:

(1) By designing the composite layer in the shielding layer to contain double-sided metal and arranging the composite layer between the insulating layer and the braid layer, the shielding performance of the shielded cable can be remarkably improved.

(2) The composite layer in the shielding layer is arranged between the insulating layer and the braided layer, so that the braided layer can be coated outside the composite layer while the composite layer is coated outside the insulating layer, the manufacturing procedures of the shielding cable are reduced, and the cost for manufacturing the shielding cable is reduced.

(3) Through arranging the metal coating between plastic layer and weaving layer and/or between plastic layer and the insulating layer, can reduce the frictional resistance between weaving layer and the cable structure who is located its inside to reduce the longitudinal stress that the weaving layer received, and then reduce the weaving layer and take place stress fracture's possibility and increase shielded cable's tensile strength.

(4) The tensile property of the conductor part can be improved by adding the copper foil wire and/or the aramid fiber wire in the conductor part.

(5) The conductor part is formed by twisting copper wires, copper foil wires and aramid fibers at small pitches, so that the softness of the conductor part can be improved, and the bending resistance of the conductor part can be improved.

Drawings

To further clarify the above and other advantages and features of embodiments of the present invention, a more particular description of embodiments of the invention will be rendered by reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope as claimed.

Fig. 1 shows a schematic cross-sectional view of a shielded electrical cable according to one embodiment of the invention.

Fig. 2 shows a flow chart of a method of manufacturing a shielded electrical cable according to an embodiment of the invention.

Fig. 3 is a flowchart showing a process of coating a shield layer outside an insulating layer in a shielded electric cable manufacturing method according to an embodiment of the present invention.

Detailed Description

While the invention will be described in further detail in connection with specific embodiments and with reference to the accompanying drawings, the following description sets forth numerous details for a thorough understanding of the invention, it will be readily apparent that the invention may be embodied in many other forms other than those described herein, and it will be readily apparent to those skilled in the art that the invention may be practiced with many modifications and alterations without departing from the spirit of the invention, and the scope of the invention should not be limited by the contents of this detailed embodiment.

This application uses specific words to describe embodiments of the application. Reference to "one embodiment," "another embodiment," and/or "some embodiments" means that a particular feature, structure, or characteristic described in connection with at least one embodiment of the application. Therefore, it is emphasized and should be appreciated that two or more references to "one embodiment" or "another embodiment" or "some embodiments" in various places in the specification are not necessarily all referring to the same embodiment. Furthermore, certain features, structures, or characteristics may be combined as suitable in one or more embodiments of the application.

It should be noted that in order to simplify the present disclosure and thereby facilitate an understanding of one or more embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure herein. This method of disclosure, however, is not intended to require more features than are expressly recited in the claims. Indeed, embodiments may have fewer than all of the features of a single embodiment disclosed below.

It should also be noted that methods, components, etc. that are well known in the art have not been described in detail in this disclosure in order to not unnecessarily obscure aspects of the embodiments of the present invention.

Referring to fig. 1, fig. 1 shows a schematic cross-sectional view of a shielded electrical cable 1 according to one embodiment of the present invention. The shielded electrical cable 1 may include a conductor portion that may be used to transmit electrical power or electrical signals. In the embodiment shown in fig. 1, the conductor portion may include copper wires 11, copper foil wires 13, and aramid wires 15. The copper foil wire 13 may include a copper foil and synthetic fibers (e.g., aramid yarn, polyester yarn, nylon yarn, etc.). For example, the copper foil wire 13 may be formed by spirally wrapping one or more copper foils on the aramid fiber wire (or the polyester fiber wire, or the nylon fiber wire) and supporting the aramid fiber wire (or the polyester fiber wire, or the nylon fiber wire). The diameter of the copper wire 11 may be approximately the same as the diameter of the copper foil wire 13. For example, the diameter of the copper wires 11 and the copper foil wires 13 may each be 0.1mm, 0.2mm, or other suitable dimensions. The copper wires 11 and the copper foil wires 13 having substantially the same diameter can maintain the structural stability of the conductor part formed by twisting. In other embodiments, the diameter of the copper wire 11 may be slightly smaller than the diameter of the copper foil wire 13. The gauge of the aramid filaments 15 may be selected to be any suitable gauge, for example, 1000D. The copper wire 11, the copper foil wire 13, and the aramid wire 15 may be twisted together by a twisting process to form a conductor part. In other embodiments, the conductor portion may include one of the copper foil wire 13 and the aramid wire 15 and the copper wire 11. In addition to the copper wire 11, by additionally adding the copper foil wire 13 and/or the aramid wire 15 having an ultra-high strength in the conductor portion, the tensile property of the conductor portion can be increased, thereby increasing the service life of the shielded cable 1, especially in an environment of bending vibration. In other embodiments, synthetic fibers such as polyester yarn and nylon yarn may be used instead of or in addition to the aramid yarn 15. In other embodiments, the conductor portion may comprise only copper wires 11. In other embodiments, the conductor portion may be formed using other conductor materials known in the art, such as silver-plated copper wire, aluminum alloys, and the like.

Referring to fig. 1, the shielded electrical cable 1 may further include an insulating layer 21, and the insulating layer 21 may be located around an outer surface of the conductor part. The insulating layer 21 may be made of an insulating material, which may be, for example, cross-linked polyethylene (XLPE), polyvinyl chloride (PVC), cross-linked polyolefin (XLPO), thermoplastic styrene elastomer (TPE-S), polyester thermoplastic elastomer (TPE-E), polyphenylene ether (PPE), polypropylene (PP), or the like.

Referring to fig. 1, the shielded cable 1 may further include a shielding layer that may be used to reduce an influence of an external electromagnetic field on power transmission or electrical signal transmission of the shielded cable 1 and to reduce an electromagnetic field radiated outward from the shielded cable 1. As shown in fig. 1, the shielding layer may include a composite layer 31 and a braid layer 33. Composite layer 31 may be positioned about an outer surface of insulation layer 21 and braided layer 33 may be positioned about an outer surface of composite layer 31. In other words, composite layer 31 may be located between insulating layer 31 and braid layer 33. In some embodiments, the composite layer 31 may include one plastic layer and two metal layers. Wherein the plastic layer is located between two metal layers. For example, the metal layer may be an aluminum layer, and the composite layer 31 may be a copolymer type double-coated aluminum-plastic composite tape. In other embodiments, the composite layer 31 may include one plastic layer and one metal layer. In some embodiments, braid 33 may be constructed of tin-plated copper wire. The tinned copper wire may comprise an electroplated tinned copper wire. The braid 33 formed by electroplating the tinned copper wire can have high tensile strength, and thus the tensile strength of the shielded cable 1 can be improved. The woven layer 33 may be woven through a precision weaving process and may be in contact with the metal layer of the composite layer 31. In embodiments where composite layer 31 includes one metal layer, the metal layer of composite layer 31 may be located between the plastic layer of composite layer 31 and braided layer 33 and immediately adjacent braided layer 33. In embodiments where composite layer 31 includes two metal layers, a first metal layer (e.g., a first aluminum layer) of composite layer 31 may be located between the plastic layer of composite layer 31 and woven layer 33 and proximate woven layer 33, and a second metal layer (e.g., a second aluminum layer) may be located between the plastic layer of composite layer 31 and insulating layer 21 and proximate insulating layer 21. In other embodiments, the shielding layer may not include a plastic layer in composite layer 31, but rather only include a metal layer and braid 33, where the metal layer may be located between insulating layer 21 and braid 33 and immediately adjacent to insulating layer 21 and braid 33.

Since the metal layer (e.g., aluminum layer) may have a smoother surface than the plastic layer or the insulating layer 21, by placing the composite layer 31 between the insulating layer 21 and the braid 33 and having the metal layer in the composite layer 31 in close proximity to the insulating layer 21 and/or the braid 33, frictional resistance between the braid 33 and the cable structure (e.g., the plastic layer, the insulating layer 21, or the conductor portion, etc.) located inside thereof may be significantly reduced, thereby reducing longitudinal stress to which the braid 33 is subjected due to relative movement between the braid 33 and the cable structure located inside thereof during vibration and bending of the shielded cable 1, thereby reducing the possibility of stress cracking of the braid 33 and increasing tensile properties of the shielded cable 1.

Compared with the existing shielded cable, the present invention can significantly improve the shielding performance of the shielded cable 1, including the surface transfer resistance performance and the shielding attenuation performance, by designing the composite layer 31 as two metal layers (e.g., aluminum layers) and disposing the composite layer 31 between the insulating layer 21 and the braid 33.

Referring to fig. 1, shielded electrical cable 1 may further include a jacket layer 41, where jacket layer 41 may be positioned about an outer surface of braid 33 and proximate to braid 33. The sheath layer 41 may be made of an insulating material, which may be, for example, cross-linked polyethylene (XLPE), polyvinyl chloride (PVC), cross-linked polyolefin (XLPO), thermoplastic styrene elastomer (TPE-S), polyester thermoplastic elastomer (TPE-E), polyphenylene ether (PPE), polypropylene (PP), or the like. In some embodiments, jacket layer 41 may be formed using a semi-extrusion process to improve flexibility of shielded electrical cable 1 and to facilitate peeling of jacket layer 41.

Referring to fig. 2, fig. 2 shows a flow diagram of a shielded electrical cable manufacturing method 200 (hereinafter method 200) according to an embodiment of the invention. In some embodiments, the shielded electrical cable 1 described above may be manufactured according to the method 200.

At step S201, a conductor portion is provided. In some embodiments, the copper wire 11, the copper foil wire 13, and the aramid wire 15 may be twisted together by a stranding process to form the conductor part. The number and size of the copper wires 11, the copper foil wires 13, and the aramid wires 15 used in the conductor portion can be selected as needed. In other embodiments, one of the copper foil wire 13 and the aramid wire 15 may be twisted together with the copper wire 11 by a stranding process to form the conductor portion. One of the copper foil wire 13 and the aramid wire 15 used in the conductor portion and the number and size of the copper wires 11 may be selected as needed. In other embodiments, synthetic fibers such as polyester yarn and nylon yarn may be used instead of or in addition to the aramid yarn 15. In other embodiments, the conductor portion may be formed by twisting a plurality of copper wires 11 together using a stranding process. In some embodiments, the conductor portion may be formed by twisting at a small pitch so as to improve the flexibility of the conductor portion, so that the bending resistance of the conductor portion may be improved, and thus the bending resistance of the shielded cable 1 may be improved.

At step S203, an insulating layer is coated outside the conductor portion. In some embodiments, an extrusion process may be used to form the insulating layer 21 around the conductor portion. In other embodiments, the pre-formed insulating layer 21 may be wrapped outside the conductor portion. The insulating layer 21 may be composed of an insulating material as described above.

At step S205, a shielding layer is wrapped outside the insulating layer. In some embodiments, the shielding layer may include a metal layer and a braid 33. In other embodiments, the shielding layer may include a composite layer 31 and a braid 33. As described above, the composite layer 31 may include plastic layers and metal layers, and the braid 33 may be braided from tinned copper wire (e.g., electroplated tinned copper wire, hot-plated tinned copper wire).

Referring to fig. 3, fig. 3 shows a flow chart of a process of coating a shielding layer outside an insulating layer in a shielded cable manufacturing method 200 according to an embodiment of the present invention. As shown in fig. 3, the step S205 of coating the shielding layer outside the insulating layer may include a step S205-1 of coating the composite layer 31 (or the metal layer) in the shielding layer outside the insulating layer 21; and step S205-3 of coating the braid 33 in the shield layer outside the composite layer 31 (or the metal layer). In step S205-1, the composite layer 31 (or the metal layer) may be wrapped outside the insulating layer 21 by a longitudinal wrapping process or a wrapping process. In step S205-3, the tinned copper wire may be woven on the outer surface of the composite layer 31 (or the metal layer) by a precision weaving process, or the pre-woven braid 33 may be coated on the outer surface of the composite layer 31 (or the metal layer). In some embodiments, the "coating the shielding layer outside the insulating layer" may be accomplished in the order shown in fig. 3 (e.g., performing step S205-1 first, then performing step S205-3). In other embodiments, step S205-1 and step S205-3 may be performed simultaneously to complete "coating the shielding layer outside the insulating layer".

In the present invention, the composite layer 31 (or the metal layer) is designed to be located between the insulating layer 21 and the braid layer 33, so that the composite layer 31 (or the metal layer) is allowed to be wrapped outside the insulating layer 21 by a longitudinal wrapping process, and the braid layer 33 is allowed to be wrapped outside the composite layer 31 (or the metal layer) (for example, a tinned copper wire is braided on the outer surface of the composite layer 31 (or the metal layer) by a precision braiding process), thereby reducing the manufacturing processes of the shielded cable 1 and reducing the cost of manufacturing the shielded cable 1.

Referring back to fig. 2, at step S207, a sheath layer is coated outside the braid layer of the shield layer. In some embodiments, jacket layer 41 may be formed around the braid of the shield layer by a semi-extrusion process. In other embodiments, pre-formed jacket layer 41 may be wrapped over braid layer 33. Jacket layer 41 may be comprised of an insulating material as described above.

The above steps are exemplary and not intended to be limiting. One skilled in the art may add one or more steps, or delete one or more of the above steps, or combine or replace one or more of the above steps, or adjust the order of one or more of the above steps according to his needs.

While the present invention has been described in accordance with its preferred embodiments, it is not intended to be limited thereto, but rather only by the scope of the appended claims.

Claims (14)

1. A shielded cable, characterized in that, shielded cable includes from inside to outside in proper order:

a conductor part;

an insulating layer (21);

a shield layer, the shield layer comprising:

a metal layer; and

a braided layer (33); and

a sheath layer (41),

wherein the metal layer is located between the insulating layer (21) and the woven layer (33).

2. The shielded electrical cable of claim 1, wherein the shielding layer further includes a plastic layer, the metal layer being located between the plastic layer and the braid and being proximate to the braid (33),

wherein the metal layer and the plastic layer together form a composite layer (31).

3. A shielded electrical cable according to claim 2, wherein the metal layer is a first aluminium layer, the composite layer (31) further comprising a second aluminium layer located between the insulating layer (21) and the plastic layer and immediately adjacent to the insulating layer (21).

4. A shielded electrical cable according to claim 1, wherein the sheath layer (41) is immediately adjacent to the braid layer (33).

5. A shielded electrical cable according to claim 1, wherein the conductor portion comprises a copper wire (11).

6. The shielded electrical cable of claim 5, wherein the conductor portion further comprises at least one of copper foil filaments (13) and synthetic fibers,

wherein the copper wire (11) is twisted with the at least one of the copper foil wire (13) and synthetic fibers, and

the synthetic fibers include at least one of: aramid yarn (15), polyester yarn, or nylon yarn.

7. The shielded cable of claim 6, wherein the diameter of the copper wire is the same as the diameter of the copper foil wire.

8. The shielded electrical cable of any one of claims 1-7, wherein the braid is braided from tinned copper wire.

9. The shielded cable of claim 8, wherein said tinned copper wire is an electroplated tinned copper wire.

10. A method of manufacturing a shielded electrical cable, the method comprising:

step S203: coating an insulating layer outside the conductor part;

step S205: coating a shielding layer outside the insulating layer, wherein the shielding layer comprises a metal layer and a woven layer, and after coating the shielding layer, the metal layer is positioned between the insulating layer and the woven layer; and

step S207: and a sheath layer is coated outside the braided layer of the shielding layer.

11. The method of claim 10, wherein step S205 comprises: step S205-1 and step S205-3 are performed simultaneously,

step S205-1 includes coating the metal layer outside the insulating layer, and step S205-3 includes coating the woven layer outside the metal layer.

12. The method of claim 11, wherein step S205-1 further comprises: and coating the metal layer outside the insulating layer by a longitudinal coating process.

13. The method of claim 11, wherein step S205-3 further comprises: and weaving the electroplating tinned copper wire on the outer surface of the metal layer by a precise weaving process.

14. The method of claim 10, further comprising:

step S201: stranding at least one of a copper foil wire and an aramid wire together with the copper wire to form the conductor part.

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