CN209232470U - A kind of high-efficient cable - Google Patents

A kind of high-efficient cable Download PDF

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Publication number
CN209232470U
CN209232470U CN201822077042.1U CN201822077042U CN209232470U CN 209232470 U CN209232470 U CN 209232470U CN 201822077042 U CN201822077042 U CN 201822077042U CN 209232470 U CN209232470 U CN 209232470U
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core
cable
outside
wrapped
copper
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张广柱
张东杰
王雪松
祝军
李斌
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Jiangsu Shangshang Cable Group Co Ltd
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Jiangsu Shangshang Cable Group Co Ltd
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • Y02A30/14Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables

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Abstract

A kind of high-efficient cable, big cable core is made of more root functionality cable twists, and big cable core gap is filled by gasket for packing;It is overlapped wrapped nonwoven fabric belts outside big cable core and constitutes nonwoven layer, inner sheath is wrapped up outside nonwoven layer, groups of metal filaments is wrapped up outside inner sheath and reticulates structure, reticular structure is wrapped with separation layer, oversheath is wrapped up outside separation layer;The radial section of the cable is round;According to line footpath size, including the biggish function cable of line footpath, the lesser function cable of line outside, is arranged successively;The immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry;The function cable includes: accessory power supply core, the first signal core group, second signal core group, wire core, active force core, circulating cooling hose: squeezing out the hollow pipe constituted by thermoplastic elastic material.This cable can realize coolant interface, cooling system, coolant design.

Description

A kind of high-efficient cable
Technical field
The technical program belongs to field of cable technology, specifically a kind of high-efficient cable manufacturing method and cable.
Background technique
That there is specific energies is low for the common lithium ion power storage battery of new-energy automobile at present, and the primary continual mileage that charges is short The problem of.Therefore, in the case where current driving force battery cannot provide more continual mileages, if the charging for being able to achieve battery is fast Speedization solves the short deadly defect of electric car continual mileage from another angle.Charge the rapid demand for becoming development. Three-element catalytic technology, gradually maturation, the specific energy of power accumulator of graphene technology are constantly being promoted simultaneously, and this requires not While realizing quick charge, meet the high-power charging of battery, realizes the powerful transmitting of charging.
Either hybrid vehicle, pure electric automobile or fuel cell car all be unable to do without high-voltage electric system.It is pure Electric car and plug-in hybrid-power automobile take more than the high voltage and several hundred amperes of high currents of 300V.The promotion meeting of voltage The requirement on electric performance of charging components, higher cost are improved, the estimated highest of following voltage is promoted to 1000V.The promotion of electric current Essential approach as high-power charging.Current electric current maximum may achieve 250A, and the cable of charging has used 95mm2Electricity Cable, to guarantee the safety of actual use.When electric current continues to increase to 400A, the cross-sectional area of conductor of traditional charging cable needs Reach 185mm2 or 240mm2, cable substance is big, outer diameter is big, inconvenient for use.If electric current rises to 500A again, charging cable Cross-sectional area of conductor, outer diameter need to continue to increase, bring cable weight, not flexible, purchase cost is high, it is inconvenient, production and processing The disadvantages of difficult to control.
The electric current of high-power charging is larger (250A is promoted to 400A or more), for the fever phenomenon for solving cable, harness Diameter therewith thicker (50mm or more), the operability of charging reduces, and the economy of scheme reduces.So having to design newly Scheme solves the heating problem of high current, transmits biggish electric current with lesser cable.
High-power charging technique includes that cooling system technology, cooling cable technology and coolant interface technology, cable temperature rise are surveyed Examination technology etc..
Summary of the invention
In order to solve the above-mentioned problems in the prior art, the technical program proposes a kind of high-efficient cable and its manufacturer Method, specifically:
A kind of high-efficient cable, big cable core is made of more root functionality cable twists, and big cable core gap is filled by gasket for packing;
It is overlapped wrapped nonwoven fabric belts outside big cable core and constitutes nonwoven layer, inner sheath, inner sheath outsourcing are wrapped up outside nonwoven layer It wraps up in groups of metal filaments and reticulates structure, reticular structure is wrapped with separation layer, oversheath is wrapped up outside separation layer;
The radial section of the cable is round;According to line footpath size, including the big function cable of line footpath, the small function of line footpath Energy cable outside, is arranged successively;The immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry;Institute Stating function cable includes:
A, accessory power supply core: auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core;Accessory power supply core has more;
B, the first signal core group: signal core is constituted by wrapping up insulating layer outside copper conductor, more signal cores are twisted to be constituted Signal core cable core, signal core cable core wrap up restrictive coating outside, and wrapped metal tape is overlapped outside signal core cable core and constitutes metal wrapping layer, gold Belong to and wrap up tincopper fuse wire braided armor outside wrapping layer, wraps up restrictive coating outside copper-wire braided layer and constitute the first signal core group;More signals When core is twisted, cable core has gasket for packing in gap;
C, second signal core group: signal core is constituted by wrapping up insulating layer outside copper conductor, more signal cores are twisted to be constituted Signal core cable core;It is overlapped wrapped metal tape outside signal core cable core and constitutes metal wrapping layer, tinned copper wire is wrapped up outside metal wrapping layer Braiding layer, copper-wire braided layer wrap up restrictive coating outside and constitute second signal core group;When more signal cores are twisted, cable core is filled out in gap Fill rope;
E, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core: by wrapped nonwoven fabric belts outside active force cable core conductor, nonwoven fabric belts outsourcing insulating layer of conductor is led It is antiblocking layers outside body insulating layer;Be inner insulating layer outside antiblocking layers, be external insulation layer outside inner insulating layer, inside and outside insulating layer it Between multiple cooling ducts are constituted by the support of more dowels;Each dowel surrounds an axisymmetrical;External insulation layer surface package Reinforcement/the blast resistance construction for thering is wire, metal tape or fiber filament to constitute;
G, the hollow pipe constituted circulating cooling hose: is squeezed out by thermoplastic elastic material;
The wrapped overlap rate of nonwoven fabric belts outside active force cable core conductor is not less than 5mm, nonwoven fabric belts with a thickness of 0.1mm; It is 0.7mm that the nominal thickness of inner insulating layer is most thin;External insulation layer is to be extruded to constitute by thermoplastic elastomer (TPE) Insulation Material, external insulation layer Nominal thickness be not less than 1.0mm.
In active force core, insulating layer of conductor is that extruded insulation material is constituted;Inner insulating layer, dowel and external insulation layer are three The same Insulation Material of layer co-extrusion is constituted.
The active force cable core conductor, the requirement of ground wire core conductor are identical, they are all to be twisted structure by multiply naked copper monofilament At;The diameter range of naked copper monofilament is 0.1mm~0.2mm;The twisted stranding distance of naked copper monofilament is no more than twisted rear conductor diameter 18 times, the stranding distance of per share bare copper wire is not more than 35 times of twisted rear strand outer diameter;Naked copper monofilament is annealing naked copper monofilament, naked copper list The oxygen content of copper is not more than 0.001% in silk, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The copper conductor of the accessory power supply core copper conductor, the copper conductor of the first signal core group and second signal core group is wanted Ask identical, they are all copper foil conductors;Copper foil conductor be copper foil docking dredge be wound on fiber surface after, then with copper monofilament be twisted structure At;Copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities are not more than 0.01701Ω.mm2/m。
In the signal core group: in the first signal core group and second signal core group, more signal cores and gasket for packing are twisted The lay ratio for constituting signal core cable core is closed no more than 20 times;Metal wrapping layer is constituted by being overlapped wrapped aluminium foil strip, wrapped to take Lid rate is not less than 25%;The braided wires diameter of copper-wire braided layer is not more than 0.15mm, count 80%~90%.
The accessory power supply core, active force core, wire core and circulating cooling hose respectively have two;First and second signal Core group respectively has one;The gasket for packing in big cable core gap is polypropylene filling rope.
Above-mentioned cable encounters problem in actual production: due to using new structure, using traditional processing technology, or It is that empirically equal be modified on traditional processing technology can not all produce the cable for reaching theoretical performance, or even can not give birth to Produce the cable for meeting custom requirements.For this purpose, the invention proposes a kind of new manufacturing method, it is exclusively used in the cable, specifically such as Under:
A kind of manufacturing method of high-efficient cable, step include:
1) conductor is first manufactured:
A, the conductor for active force core and wire core:
It is to be constituted by multiply naked copper monofilament is twisted;The diameter range of naked copper monofilament is 0.1mm~0.2mm;Naked copper monofilament twists 18 times of the stranding distance of conjunction no more than twisted rear conductor diameter, 35 of stranding distance no more than strand outer diameter after being twisted of per share bare copper wire Times;Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in naked copper monofilament, and 20 DEG C of volume resistivities are not Greater than 0.01701 Ω .mm2/m;
The line footpath of conductor is of different sizes, spare respectively as active force cable core conductor and ground wire core conductor;
B, for accessory power supply core, the copper conductor of the first signal core group and second signal core group:
It is dredged by copper foil docking after being wound on fiber surface, then is twisted and constitutes with copper monofilament;Copper monofilament is annealing naked copper monofilament, copper The oxygen content of copper is not more than 0.001% in monofilament, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The line footpath size of copper foil conductor, it is spare respectively as accessory power supply core copper conductor and signal core group copper conductor;
2) manufacture of each cable:
2.1) it manufactures active force core: taking in the conductor of active force core, and outer to extrude solidity elastic body insulated at it Material, then smearing adherence preventing material;
Then inner insulating layer, dowel and external insulation layer are extruded, finally, package reinforcement/explosion-proof layer, spare;
2.2) it manufactures accessory power supply core: taking in the copper conductor of accessory power supply core, and outer to extrude thermosetting property exhausted at it Edge material, it is spare;
2.3) it manufactures wire core: taking the conductor in wire core, and extrude heat cured insulation material outside it, it is spare;
2.4) it manufactures the first signal core group: taking in the copper conductor of the first signal core group, and outer to extrude thermosetting property exhausted at it Edge material constitutes signal core;
More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times;
Restrictive coating is wrapped up outside signal core cable core, is overlapped wrapped aluminium foil strip outside signal core cable core, wrapped overlap rate is not less than 25%;
Tincopper fuse wire braided armor is wrapped up outside aluminium foil strip again as metal screen layer, the diameter of tinned copper wire braided wires is little In 0.15mm, count 80%~90%;
The outer extrude sheath material of tincopper fuse wire braided armor, it is spare;
2.5) it manufactures second signal core group: taking in the copper conductor of second signal core group, and outer to extrude thermosetting property exhausted at it Edge material constitutes signal core;
More and gasket for packing core and gasket for packing is twisted constitutes signal core cable core, lay ratio is not more than 20 times;
Wrapped aluminium foil strip is overlapped outside signal core cable core, wrapped overlap rate is not less than 25%;
Tincopper fuse wire braided armor is wrapped up outside aluminium foil strip again as metal screen layer, the diameter of tinned copper wire braided wires is little In 0.15mm, count 80%~90%;
It is squeezed outside tincopper fuse wire braided armor and embraces protective cover material, it is spare;
The twisted knot of first and second signal core group is not away from identical;
2.6) hollow pipe constituted circulating cooling hose: is squeezed out by thermoplastic elastic material;
3) step 2.1~2.6) made from after cable and circulating cooling hose and gasket for packing be twisted into cable core jointly, then Wrapped nonwoven fabric belts constitute nonwoven layer;
4) oversheath material is extruded outside nonwoven fabric belts, and restrictive coating is made;The netted knot that wire is constituted is wrapped up outside inner sheath Structure, reticular structure wrap up separation layer outside, and the outer extrude sheath material of separation layer constitutes oversheath.
State in step 1): during process, the hauling speed of conductor is 9.696 ± 2m/min, and traction revolving speed is 10~15 Grade;
By 1+6+12+18 disk hauling cage machine process, 1+6 cage revolving speed is (76 ± 3) r/min, and 12 disk cage revolving speeds are (75.9 ± 3) r/min, 18 disk cage revolving speeds are (66 ± 3) r/min, and twisted wire outermost layer pitch is not more than 160mm.
In the step 3):
Cable core gap uses non-hygroscopic high temperature resistant twisting type gasket for packing;Gasket for packing fills diameter and uses 9 4.0mm;
Stranding twisting pitch range is outer diameter after 12~14 times of cores are twisted;
During process, 85~90r/min of cage revolving speed (preferably 92.2r/min) of hauling cage machine, 4~5m/ of hauling speed Min (preferably 8.32 4m/min), 10~20r/min of taping head revolving speed;
Wrapped overlap rate is overlapped not less than 25% with nonwoven fabric belts;When wrapped, hauling speed is 4~5m/min, wrapped Pitch is 40 ± 5mm, and the tension on nonwoven fabric belts is 40~45N (preferably 40N);Lapping direction is dextrad, twining package tape with a thickness of 0.1mm。
Step 2.1)~2.5) in, according to respective insulation layers structure, using corresponding mold, extruded insulation material, and It is cooling;Wherein:
Step 2.1)~2.5) in heat cured insulation material, extrude requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;The temperature of each warm area of head and machine neck is all 185 ± 5 DEG C;
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone;
Insulation Material accelerates to complete to irradiate after squeezing out by electronics, 1.2~2.1MEV of irradiation energy, line 20mA~26mA, Energy ratio 1.2~2.0,30~120m/min of line speed;
In the step 2.1), the Insulation Material of inner insulating layer, dowel and external insulation layer is all thermoplastic elastomer (TPE) insulation Material, mold is Three-layer co-extrusion mold, and mold core, die sleeve, mold core aperture=conductor diameter+0.2mm are matched on the head of extruding machine; Three-layer co-extruded extrudes requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 155 ± 5 DEG C of 2nd area, 3rd area 165 ± 5 DEG C, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;The temperature of each warm area of head and machine neck is all 190 ± 5 DEG C;
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In the step 4), oversheath is obtained using extruding machine extrude sheath material, and an area is pan feeding section, 2nd area, 3rd area For fluxing zone, 4th area, 5th area are that homogenizing zone is fed to discharging direction, discharging direction, fuselage warm area certainly are as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;Head, machine neck each warm area temperature Degree is all 195 ± 5 DEG C;
One area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In this example, the twisted equipment of big cable core uses back-twisting cable-former, and equipment easily uses 3+6 cable-former, cable-former The line equipment wheeled unwrapping wire frame of pay off rack after totally 9 draw drums and 2;Draw drum be set to A1, A2, A3, A4, A5, A6, A7, A8 and A9;A1 places the first signal core group, and A2 places a wire core, and A3 places an auxiliary core, and A4 places an auxiliary Core, A5 place a wire core, and A6 places second signal core group, and A7 places a master core, and A8 places a circulating cooling Hose, A9 place a master core, and the wheeled unwrapping wire frame of pay off rack places a circulating cooling hose after two;
The stranding wire parallel module of cable-former uses tungsten steel die, and internal orifice dimension is equal to core and is twisted outer diameter, and stranding direction is dextrad.
This cable passes through the particular design of material, structure, is full of in charging time 15min, and continue a journey 400km, cable weight Amount, outer diameter reduce, and less than 15 DEG C, the application of the technology, solution China new-energy automobile that can be inexpensive fills for charging fever temperature rise The bottleneck problem of electric time length, is conducive to the popularization and use of new-energy automobile.
Using cable made from this method, it is able to satisfy design requirement, meanwhile, qualification rate reaches 98% or more.
This cable can realize coolant interface, cooling system, coolant design, the decline of active force insulated wire cores conductor It is full of in 30%, charging time 15min, cable weight, outer diameter reduce, the application of the technology, and solution China that can be inexpensive is new The bottleneck problem of energy automobile charging time length, is conducive to the popularization and use of new-energy automobile.
Detailed description of the invention
Fig. 1 is the radial cross section of the present embodiment cable,
In figure: active force cable core conductor 1, insulating layer of conductor 2, the inner insulating layer 3 of active force core, cooling duct 4, active External insulation layer 5, dowel 6, accessory power supply core copper conductor 7, the auxiliary power supply line core insulation layer 8, ground wire core conductor of line of force core 9, the insulating layer outside the copper conductor of ground wire core insulating barrier 10, the copper conductor 11 of first/binary signal core group, first/binary signal core group 12, the gasket for packing 13 of first/binary signal core group, metal wrapping layer 14, tincopper fuse wire braided armor 15, circulating cooling hose 16, big The gasket for packing 17 in cable core gap, the nonwoven layer 18 outside big cable core, oversheath 19.
Specific embodiment
The technical program is further described below combined with specific embodiments below:
Such as Fig. 1, a kind of cable is made of big cable core more root functionality cable twists, and big cable core gap is filled by gasket for packing;
It is overlapped wrapped nonwoven fabric belts outside big cable core and constitutes nonwoven layer, inner sheath, inner sheath outsourcing are wrapped up outside nonwoven layer It wraps up in groups of metal filaments and reticulates structure, reticular structure is wrapped with separation layer, oversheath is wrapped up outside separation layer;
The radial section of the cable is round;According to line footpath size, including the big function cable of line footpath, the small function of line footpath Energy cable outside, is arranged successively;The immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry;Institute Stating function cable includes:
A, accessory power supply core: auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core;Accessory power supply core has more;
B, the first signal core group: signal core is constituted by wrapping up insulating layer outside copper conductor, more signal cores are twisted to be constituted Signal core cable core, signal core cable core wrap up restrictive coating outside, and wrapped metal tape is overlapped outside signal core cable core and constitutes metal wrapping layer, gold Belong to and wrap up tincopper fuse wire braided armor outside wrapping layer, wraps up restrictive coating outside copper-wire braided layer and constitute the first signal core group;More signals When core is twisted, cable core has gasket for packing in gap;
C, second signal core group: signal core is constituted by wrapping up insulating layer outside copper conductor, more signal cores are twisted to be constituted Signal core cable core;It is overlapped wrapped metal tape outside signal core cable core and constitutes metal wrapping layer, tinned copper wire is wrapped up outside metal wrapping layer Braiding layer, copper-wire braided layer wrap up restrictive coating outside and constitute second signal core group;When more signal cores are twisted, cable core is filled out in gap Fill rope;
E, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core: by wrapped nonwoven fabric belts outside active force cable core conductor, nonwoven fabric belts outsourcing insulating layer of conductor is led It is antiblocking layers outside body insulating layer;Be inner insulating layer outside antiblocking layers, be external insulation layer outside inner insulating layer, inside and outside insulating layer it Between multiple cooling ducts are constituted by the support of more dowels;Each dowel surrounds an axisymmetrical;External insulation layer surface package Reinforcement/the blast resistance construction for thering is wire, metal tape or fiber filament to constitute;
G, the hollow pipe constituted circulating cooling hose: is squeezed out by thermoplastic elastic material;
The wrapped overlap rate of nonwoven fabric belts outside active force cable core conductor is not less than 5mm, nonwoven fabric belts with a thickness of 0.1mm; It is 0.7mm that the nominal thickness of inner insulating layer is most thin;External insulation layer is to be extruded to constitute by thermoplastic elastomer (TPE) Insulation Material, external insulation layer Nominal thickness be not less than 1.0mm.
In active force core, insulating layer of conductor is that extruded insulation material is constituted;Inner insulating layer, dowel and external insulation layer are three The same Insulation Material of layer co-extrusion is constituted.
The active force cable core conductor, the requirement of ground wire core conductor are identical, they are all to be twisted structure by multiply naked copper monofilament At;The diameter range of naked copper monofilament is 0.1mm~0.2mm;The twisted stranding distance of naked copper monofilament is no more than twisted rear conductor diameter 18 times, the stranding distance of per share bare copper wire is not more than 35 times of twisted rear strand outer diameter;Naked copper monofilament is annealing naked copper monofilament, naked copper list The oxygen content of copper is not more than 0.001% in silk, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The copper conductor of the accessory power supply core copper conductor, the copper conductor of the first signal core group and second signal core group is wanted Ask identical, they are all copper foil conductors;Copper foil conductor be copper foil docking dredge be wound on fiber surface after, then with copper monofilament be twisted structure At;Copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities are not more than 0.01701Ω.mm2/m。
In the signal core group: in the first signal core group and second signal core group, more signal cores and gasket for packing are twisted The lay ratio for constituting signal core cable core is closed no more than 20 times;Metal wrapping layer is constituted by being overlapped wrapped aluminium foil strip, wrapped to take Lid rate is not less than 25%;The braided wires diameter of copper-wire braided layer is not more than 0.15mm, count 80%~90%.
In this example, the accessory power supply core, active force core, wire core and circulating cooling hose respectively have two;The first, Binary signal core group respectively has one;The gasket for packing in big cable core gap is polypropylene filling rope.
In embodiment, thermoplastic elastic material is required to include: Halogen, fire-retardant, environmentally friendly;Tensile strength is not less than 10MPa; Elongation is not less than 300%;
135 degrees Celsius, hot air aging in 7 days, tensile strength are not less than 10MPa, and elongation is not less than 300%, change rate No more than 25%;
- 40 degrees Celsius of cryogenic tensiles are not less than 30%, are heat-shrinked and are not less than 2%;
90 celsius temperature pressure impressions are not more than 50%;
Insulation resistance constant is not less than 1 × 1015Ω cm, hardness are not less than 85A (shore), and dielectric strength is not less than 20kV/mm。
The performance requirement of circulating cooling hose:
Hardness is not less than 90A (shore), and dimensional discrepancy is not more than ± 0.5mm, and dielectric strength is not less than 20kV/mm, volume Resistivity 10^15 Ω cm,
It is not less than 3670 when being not less than 3.67,20 DEG C when insulation resistance constant is 90 DEG C,
Original mechanical performance tensile strength is not less than 15MPa, elongation at break not in 300%,
158 DEG C, mechanical performance after 168h aging, tensile strength and elongation at break change rate are not more than ± 30%,
Heat extends 250 DEG C, 20min,
Elongation is not more than 100%,
Permanent set is not more than 15%,
It is anti-tear to be not less than 20N/mm,
150 DEG C, 1h, do not crack, wear-resisting to be not less than 10,000 times,
90 DEG C of high temperature, 1h, thermal deformation are not more than 20%,
- 40 DEG C, 4h, elongation are not less than 30%,
150 DEG C, 1h shrink and are not more than 1%,
Water-fast: 90 DEG C, 168h, variation in tensile strength are not more than ± 25%,
Water-fast: 20 DEG C, 168h, variation in tensile strength are not more than ± 25%,
Standard acid: 20 DEG C, 168h, variation in tensile strength are not more than ± 25%,
Standard base (SB): 20 DEG C, 168h, variation in tensile strength are not more than ± 25%,
Pressure-bearing: under the conditions of 90 degree, 1.0MPa, 30min, tubing is indeformable, does not rupture;
Pressure-bearing: under the conditions of 20 degree, 1.2MPa, 30min, tubing is indeformable, does not rupture.
Heat cured insulation material is crosslinked.Insulation Material temperature resistant grade is 125 degree, Halogen, fire-retardant, environmentally friendly,
Pristine tensile strength is not less than 8MPa, and elongation is not less than 200%,
158 degree, after 7 days heat ageings, tensile strength, elongation change rate are not more than 30%,
- 40 degree cryogenic tensiles are not less than 30%, are heat-shrinked and are not less than 2%,
90 degree of high temperature pressure impressions are not more than 50%,
Insulation resistance constant is not less than 1*1015Ω cm,
Hardness is not less than 85A (shore),
Dielectric strength is not less than 20kV/mm,
250 degree of hot elongating temperature, elongation are not more than 100%, and permanent set is not more than 25%, and insulation nominal thickness is most Thin 0.7mm, does not set the upper limit.
The manufacturing method of above-mentioned cable is described as follows:
A kind of manufacturing method of high-efficient cable, step include:
1) conductor is first manufactured:
A, the conductor for active force core and wire core:
It is to be constituted by multiply naked copper monofilament is twisted;The diameter range of naked copper monofilament is 0.1mm~0.2mm;Naked copper monofilament twists 18 times of the stranding distance of conjunction no more than twisted rear conductor diameter, 35 of stranding distance no more than strand outer diameter after being twisted of per share bare copper wire Times;Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in naked copper monofilament, and 20 DEG C of volume resistivities are not Greater than 0.01701 Ω .mm2/m;
The line footpath of conductor is of different sizes, spare respectively as active force cable core conductor and ground wire core conductor;
B, for accessory power supply core, the copper conductor of the first signal core group and second signal core group:
It is dredged by copper foil docking after being wound on fiber surface, then is twisted and constitutes with copper monofilament;Copper monofilament is annealing naked copper monofilament, copper The oxygen content of copper is not more than 0.001% in monofilament, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m;
The line footpath size of copper foil conductor, it is spare respectively as accessory power supply core copper conductor and signal core group copper conductor;
2) manufacture of each cable:
2.1) it manufactures active force core: taking in the conductor of active force core, and outer to extrude solidity elastic body insulated at it Material, then smearing adherence preventing material;
Then inner insulating layer, dowel and external insulation layer are extruded, finally, package reinforcement/explosion-proof layer, spare;
2.2) it manufactures accessory power supply core: taking in the copper conductor of accessory power supply core, and outer to extrude thermosetting property exhausted at it Edge material, it is spare;
2.3) it manufactures wire core: taking the conductor in wire core, and extrude heat cured insulation material outside it, it is spare;
2.4) it manufactures the first signal core group: taking in the copper conductor of the first signal core group, and outer to extrude thermosetting property exhausted at it Edge material constitutes signal core;
More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times;
Restrictive coating is wrapped up outside signal core cable core, is overlapped wrapped aluminium foil strip outside signal core cable core, wrapped overlap rate is not less than 25%;
Tincopper fuse wire braided armor is wrapped up outside aluminium foil strip again as metal screen layer, the diameter of tinned copper wire braided wires is little In 0.15mm, count 80%~90%;
The outer extrude sheath material of tincopper fuse wire braided armor, it is spare;
2.5) it manufactures second signal core group: taking in the copper conductor of second signal core group, and outer to extrude thermosetting property exhausted at it Edge material constitutes signal core;
More and gasket for packing core and gasket for packing is twisted constitutes signal core cable core, lay ratio is not more than 20 times;
Wrapped aluminium foil strip is overlapped outside signal core cable core, wrapped overlap rate is not less than 25%;
Tincopper fuse wire braided armor is wrapped up outside aluminium foil strip again as metal screen layer, the diameter of tinned copper wire braided wires is little In 0.15mm, count 80%~90%;
It is squeezed outside tincopper fuse wire braided armor and embraces protective cover material, it is spare;
The twisted knot of first and second signal core group is not away from identical;
2.6) hollow pipe constituted circulating cooling hose: is squeezed out by thermoplastic elastic material;
3) step 2.1~2.6) made from after cable and circulating cooling hose and gasket for packing be twisted into cable core jointly, then Wrapped nonwoven fabric belts constitute nonwoven layer;
4) oversheath material is extruded outside nonwoven fabric belts, and restrictive coating is made;The netted knot that wire is constituted is wrapped up outside inner sheath Structure, reticular structure wrap up separation layer outside, and the outer extrude sheath material of separation layer constitutes oversheath.
In the step 1): during process, the hauling speed of conductor is 9.696 ± 2m/min, traction revolving speed is 10~ 15 grades;
By 1+6+12+18 disk hauling cage machine process, 1+6 cage revolving speed is (76 ± 3) r/min, and 12 disk cage revolving speeds are (75.9 ± 3) r/min, 18 disk cage revolving speeds are (66 ± 3) r/min, and twisted wire outermost layer pitch is not more than 160mm.
In the step 3):
Cable core gap uses non-hygroscopic high temperature resistant twisting type gasket for packing;Gasket for packing fills diameter and uses 9 4.0mm;
Stranding twisting pitch range is outer diameter after 12~14 times of cores are twisted;
During process, 85~90r/min of cage revolving speed (preferably 92.2r/min) of hauling cage machine, 4~5m/ of hauling speed Min (preferably 8.32 4m/min), 10~20r/min of taping head revolving speed;
Wrapped overlap rate is overlapped not less than 25% with nonwoven fabric belts;When wrapped, hauling speed is 4~5m/min, wrapped Pitch is 40 ± 5mm, and the tension on nonwoven fabric belts is 40~45N (preferably 40N);Lapping direction is dextrad, twining package tape with a thickness of 0.1mm。
Step 2.1)~2.5) in, according to respective insulation layers structure, using corresponding mold, extruded insulation material, and It is cooling;Wherein:
Step 2.1)~2.5) in heat cured insulation material, extrude requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area;The temperature of each warm area of head and machine neck is all 185 ± 5 DEG C;
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone;
Insulation Material accelerates to complete to irradiate after squeezing out by electronics, 1.2~2.1MEV of irradiation energy, line 20mA~26mA, Energy ratio 1.2~2.0,30~120m/min of line speed;
In the step 2.1), the Insulation Material of inner insulating layer, dowel and external insulation layer is all thermoplastic elastomer (TPE) insulation Material, mold is Three-layer co-extrusion mold, and mold core, die sleeve, mold core aperture=conductor diameter+0.2mm are matched on the head of extruding machine; Three-layer co-extruded extrudes requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 155 ± 5 DEG C of 2nd area, 3rd area 165 ± 5 DEG C, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;The temperature of each warm area of head and machine neck is all 190 ± 5 DEG C;
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In the step 4), oversheath is obtained using extruding machine extrude sheath material, and an area is pan feeding section, 2nd area, 3rd area For fluxing zone, 4th area, 5th area are that homogenizing zone is fed to discharging direction, discharging direction, fuselage warm area certainly are as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area;Head, machine neck each warm area temperature Degree is all 195 ± 5 DEG C;
One area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In this example, the twisted equipment of big cable core uses back-twisting cable-former, and equipment easily uses 3+6 cable-former, cable-former The line equipment wheeled unwrapping wire frame of pay off rack after totally 9 draw drums and 2;Draw drum be set to A1, A2, A3, A4, A5, A6, A7, A8 and A9;A1 places the first signal core group, and A2 places a wire core, and A3 places an auxiliary core, and A4 places an auxiliary Core, A5 place a wire core, and A6 places second signal core group, and A7 places a master core, and A8 places a circulating cooling Hose, A9 place a master core, and the wheeled unwrapping wire frame of pay off rack places a circulating cooling hose after two;
The stranding wire parallel module of cable-former uses tungsten steel die, and internal orifice dimension is equal to core and is twisted outer diameter, and stranding direction is dextrad.
Thermoset elastomer materials are EVA substrate, cooperation cooperation toughened system, flame-retardant system, preventing aging system and lubrication System is formed through physics and chemical modification, and tear resistance is not less than 15N/mm, and water resistance passes through 80 DEG C × 168 test requirements documents, The hardness that insulate is not less than 90 shore A, and 3670M Ω km is not less than at 20 DEG C of insulation resistance constant, and insulation tensile strength is not less than 10MPa, elongation at break are not less than 300%, and 158 DEG C, 168h postcondition, variation in tensile strength are not more than ± 30%, fracture Elongation change rate is not more than ± 30%, under the conditions of -40 DEG C, and elongation at break is not less than 30%, and 90 DEG C of whens are not less than 3.67,90 High temperature pressure impression is not more than 50% under the conditions of DEG C;It is shunk under the conditions of 130 DEG C and is not more than 4%, be not precipitated, is halogen-free, no red phosphorus, Meet environmental protection and REACH requirement.
Insulation Material accelerates to complete irradiation by electronics after squeezing out, after insulating layer sample preparation is taken after irradiation, under the conditions of 250 DEG C, 15min, elongation at break are not more than 100%, and permanent set is not more than ± 25%;
Thermoplastic elastomer (TPE), material is using elastomer as substrate, cooperation toughened system, flame-retardant system, preventing aging system and profit Gliding mass system forms through physics and chemical modification, and tear resistance is not less than 15N/mm, and water resistance is wanted by 80 DEG C × 168 tests It asks, insulation hardness is not less than 85 shore A, 3670M Ω km is not less than at 20 DEG C of insulation resistance constant, insulation tensile strength is not It is not less than 300% less than 10MPa, elongation at break, 135 DEG C, 168h postcondition, tensile strength are not less than 10MPa, change rate No more than ± 25%, elongation at break is not less than 300%, change rate is not more than ± 25%, under the conditions of -40 DEG C, elongation at break High temperature pressure impression is not more than 50% under the conditions of being not less than 3.67,90 DEG C when not less than 30%, 90 DEG C;It is shunk under the conditions of 130 DEG C It no more than 4%, is not precipitated, is halogen-free, no red phosphorus, meeting environmental protection and REACH requirement.In the step 3, packing material is resistance to height Temperature, twisting type gasket for packing, the main substrate of the gasket for packing are polypropylene material, place different rulers for gap different in cable core Very little gasket for packing;In addition, packing material insulation is under the conditions of 125 DEG C, 240h, material can not deform, aging, decomposition, Phenomena such as fragmentation, still keeps original good form.
In step 4), protective cover material is cooperation toughened system, flame-retardant system, preventing aging system and profit using elastomer as substrate Gliding mass system is changed to through physics and chemistry, has good flexibility, oil resistant, wear-resisting, anti-UV, hydrolysis, acid and alkali-resistance are fire-retardant excellent More, it is not precipitated, is halogen-free, no red phosphorus, the weather of resistance to 720h, by single vertical combustion test, tearing toughness is not less than 20N/ mm.Under the conditions of 105 DEG C, 4h, the slippage power of cable still keeps 500N or more.
Thermoplastic elastic material (such as TPE) requires as high electrical, ageing-resistant, resistance to -40 DEG C of low temperature, hydrolysis, chemically-resistant Liquid.
Protective cover material (such as TPE or TPU) requirement of the restrictive coating are as follows: high anti-tear, high abrasion, water-fast, weather-proof, -40 DEG C resistance to Low temperature, fire-retardant, environmentally friendly, chemically-resistant liquid, antiultraviolet.
The ground wire core insulating barrier, auxiliary core, signal wire core insulation layer material (such as XLPO or EY) are as follows: high rigidity, height Electrical, resistance to -40 DEG C of low temperature, ageing-resistant, fire-retardant and thermosetting property.
The twisting pitch of signal core cable core in each signal core group is different.To avoid signal core group from interfering, two groups twisted Pitch is different.
Inner insulating layer, dowel, external insulation layer are wrapped in outside conductor using three-layer co-extruded mode and are wrapped in outside conductor.Mould The aperture of core is greater than conductor diameter, mold core aperture=conductor diameter+0.3mm;When insulating exruded machine utilization be maintained at 110A~ 125A, air pressure set 8MPa, and otherwise breach occur in interior insulation and external insulation, can not squeeze out.
Wherein, in the selection of above-mentioned technological parameter, when selecting median and preferred value, an excellent rate of product When reaching 99.8%, and relax in value range, although the available product that conforms to quality requirements, one time excellent rate exists more Between 98~99%.
As a result it detects, the characteristics of this cable includes:
1) charging time shortens
DC charging foreshortens to 15min, realizes that electric car is continued a journey 400 kilometers, and the cooling cable charging time shortens 90%.
2) cable purchase cost reduces: cable buying drop sheet 15%~20%.
3) cable weight mitigation, outer diameter are small
The cooling outside diameter of cable control of high-power quick charge is in 46mm hereinafter, the 400A direct current charging cable finished product that compares Cable weight decline 25%.
4) temperature rise is small
High-power quick charge use cools down cable, is full of in 15min, realizes that electric car is continued a journey 400 kilometers, temperature rise does not surpass Cross 35 DEG C.
5) high electrical
The product of inspection is detected through third party's pattern, actual measurement insulation, the volume resistivity actual measurement 10 of sheath15Ω .mm, is filled up The world ISO, GB country new-energy automobile silicon rubber car high pressure 109Ω.mm。
6) high and low temperature resistance
Active force power supply meets 125 DEG C of operating conditions and uses.Meet -40 DEG C of low-temperature impacts, -40 DEG C of low temperature winding, -40 DEG C it is low Warm tension test requirement.
7) fire retardancy test:
Meet the single burning of GB/T18380.12.
8) chemical-resistant reagent
Meet method one, the method two, battery acid test requirements document in ISO6722-1 standard simultaneously, meets working condition requirement.
9) resistance to vehicle rolls
This cable is rolled through vehicle reciprocal 3 times, is applied voltage tester, cooling cycle test, is met and reuse.

Claims (5)

1. a kind of high-efficient cable, it is characterized in that being made of big cable core more root functionality cable twists, big cable core gap is filled out by gasket for packing It fills;
It is overlapped wrapped nonwoven fabric belts outside big cable core and constitutes nonwoven layer, inner sheath is wrapped up outside nonwoven layer, gold is wrapped up outside inner sheath Belong to silk and form reticular structure, reticular structure is wrapped with separation layer, oversheath is wrapped up outside separation layer;
The radial section of the cable is round;According to line footpath size, including the big function cable of line footpath, the small functional line of line footpath Cable outside, is arranged successively;The immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry;The function Can cable include:
A, accessory power supply core: auxiliary power supply line is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Core;Accessory power supply core has more;
B, the first signal core group: the first signal core is constituted by wrapping up insulating layer outside copper conductor, more first signal cores are twisted The first signal core cable core is constituted, restrictive coating is wrapped up outside the first signal core cable core, wrapped metal tape is overlapped outside the first signal core cable core Metal wrapping layer is constituted, tincopper fuse wire braided armor is wrapped up outside metal wrapping layer, restrictive coating is wrapped up outside copper-wire braided layer and constitutes first Signal core group;When more first signal cores are twisted, there is gasket for packing in the first signal core cable core gap;
C, second signal core group: second signal core is constituted by wrapping up insulating layer outside copper conductor, more second signal cores are twisted Constitute second signal core cable core;It is overlapped wrapped metal tape outside second signal core cable core and constitutes metal wrapping layer, outside metal wrapping layer Tincopper fuse wire braided armor is wrapped up, restrictive coating is wrapped up outside copper-wire braided layer and constitutes second signal core group;More second signal cores twist When conjunction, second signal core cable core has gasket for packing in gap;
E, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor;
F, active force core: by wrapped nonwoven fabric belts outside active force cable core conductor, nonwoven fabric belts outsourcing insulating layer of conductor, conductor is exhausted It is antiblocking layers outside edge layer;Be inner insulating layer outside antiblocking layers, be external insulation layer outside inner insulating layer, between inside and outside insulating layer by More dowel supports constitute multiple cooling ducts;Each dowel surrounds an axisymmetrical;External insulation layer is coated with gold Belong to reinforcement/blast resistance construction that silk, metal tape or fiber filament are constituted;
The Insulation Material of inner insulating layer, dowel and external insulation layer is all thermoplastic elastomer (TPE) Insulation Material, inner insulating layer, dowel and External insulation layer is that three-layer co-extruded thermoplastic elastomer (TPE) Insulation Material is constituted;
G, the hollow pipe constituted circulating cooling hose: is squeezed out by thermoplastic elastic material.
2. cable according to claim 1, it is characterized in that the wrapped overlap rate of nonwoven fabric belts outside active force cable core conductor is not Less than 5mm, nonwoven fabric belts with a thickness of 0.1mm;It is 0.7mm that the nominal thickness of inner insulating layer is most thin;The nominal thickness of external insulation layer Degree is not less than 1.0mm.
3. cable according to claim 1, it is characterized in that the active force cable core conductor, the requirement phase of ground wire core conductor Together, they are constituted by multiply naked copper monofilament is twisted;The diameter range of naked copper monofilament is 0.1mm~0.2mm;Naked copper monofilament twists 18 times of the stranding distance of conjunction no more than twisted rear conductor diameter, 35 of stranding distance no more than strand outer diameter after being twisted of per share bare copper wire Times;Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in naked copper monofilament, 20 DEG C of bodies of naked copper monofilament Product resistivity is not more than 0.01701 Ω .mm2/m;
The requirement phase of the copper conductor of the accessory power supply core copper conductor, the copper conductor of the first signal core group and second signal core group Together, they are all copper foil conductors;Copper foil conductor is after copper foil docking dredges and is wound on fiber surface, then with copper monofilament is twisted constitutes;Copper Monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities of copper monofilament are little In 0.01701 Ω .mm2/m。
4. cable according to claim 1, it is characterized in that in the signal core group: the first signal core group and second signal core In group, more signal cores and the twisted lay ratio for constituting signal core cable core of gasket for packing are not more than 20 times;Metal wrapping layer is It is made of the aluminium foil strip for being overlapped wrapped, wrapped overlap rate is not less than 25%;The braided wires diameter of copper-wire braided layer is not more than 0.15mm, count 80%~90%.
5. cable according to claim 1, it is characterized in that the accessory power supply core, active force core, wire core and following Ring cooling tube respectively has two;First and second signal core group respectively has one;The gasket for packing in big cable core gap is polypropylene filling rope.
CN201822077042.1U 2018-12-11 2018-12-11 A kind of high-efficient cable Active CN209232470U (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020119308A1 (en) * 2018-12-11 2020-06-18 江苏上上电缆集团有限公司 Method for fabricating hollow electric cable for charging new energy vehicle and electric cable

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020119308A1 (en) * 2018-12-11 2020-06-18 江苏上上电缆集团有限公司 Method for fabricating hollow electric cable for charging new energy vehicle and electric cable

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