CN214956126U - Thick wall aluminum alloy core high tension cable for new energy automobile - Google Patents

Thick wall aluminum alloy core high tension cable for new energy automobile Download PDF

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Publication number
CN214956126U
CN214956126U CN202121449748.1U CN202121449748U CN214956126U CN 214956126 U CN214956126 U CN 214956126U CN 202121449748 U CN202121449748 U CN 202121449748U CN 214956126 U CN214956126 U CN 214956126U
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layer
aluminum alloy
new energy
energy automobile
thick
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CN202121449748.1U
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陈梦迪
许军
梁马超
吴晴
王皓予
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Aerospace Electric Group Co ltd
Aerospace Rich Cable Co ltd
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Aerospace Electric Group Co ltd
Aerospace Rich Cable Co ltd
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Abstract

The utility model discloses a thick wall aluminum alloy core high voltage cable for a new energy automobile, which comprises an insulation wire core, a braid layer, a belting layer and a sheath layer; the braided layer is coated on the outer side of the insulated wire core, the belting layer is coated on the outer side of the braided layer, and the sheath layer is coated on the outer side of the belting layer; the restrictive coating includes inner sheath layer and oversheath layer, and the inner sheath layer cladding is in the belting layer outside, and the oversheath layer cladding is in the inner sheath layer outside. The utility model can effectively avoid the weaving burr from piercing the sheath and the spark breakdown is generated by arranging the belting layer between the weaving layer and the sheath layer; through setting up double-deck thick wall restrictive coating, can make the cable have better compliance when improving mechanical properties.

Description

Thick wall aluminum alloy core high tension cable for new energy automobile
Technical Field
The utility model belongs to the technical field of the cable technique and specifically relates to a thick wall aluminum alloy core high tension cable for new energy automobile is related to.
Background
At present, the development of the automotive industry faces three serious problems: namely oil consumption, environmental protection and safety; the light weight, environmental protection and new energy of automobiles become the development trend of the global automobile industry. The automobile lightweight technology improves the energy economy of the whole automobile by reducing the self mass, thereby achieving the purposes of reducing oil consumption and reducing emission. Currently, the weight reduction of automobiles as a future development trend has penetrated the aspects of automobile manufacturing, such as: the automobile wire harness hidden in the automobile is like the automobile 'blood vessels' and 'nerves' and is large in number, so that the automobile wire harness is more likely to be light in weight.
In recent years, the price of copper metal is increased once and then, the cost of the automobile high-voltage cable using the copper metal as a conductor is increased sharply, China needs to import a large amount of copper every year, the price of the copper is influenced by the international market and fluctuates greatly, and a plurality of uncertain factors are caused to the automobile industry. With the high-speed development of the new energy automobile industry, the demand of the in-automobile high-voltage cable for the new energy automobile is increased, and the performance of the cable is high or low, so that various service performances of the new energy automobile are directly influenced.
Chinese patent CN107871549A discloses an aluminum alloy cable for vehicle, which comprises an aluminum alloy conductor, and an insulating layer, a shielding layer and an outer protective layer sequentially coated outside the aluminum alloy conductor, wherein the insulating layer is composed of 125 ℃ irradiation cross-linked polyolefin insulating material, the shielding layer is woven by copper wires or tinned copper wires, and the outer protective layer is a 125 ℃ high-flexibility thermoplastic elastomer. The aluminum alloy cable has high tensile strength, high conductivity and high softness, the bending radius of a finished product is not less than 3 times of the outer diameter of the cable, the mass of the aluminum alloy cable is reduced by half compared with that of a copper core cable, and the price of the aluminum alloy cable is nearly 40%. However, the cable is directly extruded outside the braided layer, so that braided patterns are easily formed on the surface of the sheath, and the braided burrs pierce the sheath, so that spark breakdown is caused.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to overcome above-mentioned technique not enough, provide a new energy automobile is with thick wall aluminum alloy core high tension cable, through wrapping up the band layer outside the weaving layer, avoid directly crowded package outside the weaving layer, weave the technical problem that the burr easily impaled the sheath, lead to the spark breakdown among the solution prior art.
In order to achieve the technical purpose, the technical scheme of the utility model provides a thick-wall aluminum alloy core high-voltage cable for a new energy automobile, which comprises an insulation wire core, a braid layer, a belting layer and a sheath layer; the braided layer is coated on the outer side of the insulated wire core, the belting layer is coated on the outer side of the braided layer, and the sheath layer is coated on the outer side of the belting layer;
the restrictive coating includes inner sheath layer and oversheath layer, and the inner sheath layer cladding is in the belting layer outside, and the oversheath layer cladding is in the inner sheath layer outside.
Compared with the prior art, the beneficial effects of the utility model include:
the utility model can effectively avoid the weaving burr from piercing the sheath and the spark breakdown is generated by arranging the belting layer between the weaving layer and the sheath layer; through setting up double-deck thick wall restrictive coating, can make the cable have better compliance when improving mechanical properties.
Drawings
Fig. 1 is a schematic structural diagram of an embodiment of a thick-wall aluminum alloy core high-voltage cable for a new energy automobile;
in the figure: 1-insulating wire core 1, 2-braided layer, 3-belting layer, 4-restrictive coating, 11-aluminum alloy conductor, 12-insulating layer, 41-inner sheath layer, 42-outer sheath layer.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Referring to fig. 1, the utility model provides a thick wall aluminum alloy core high voltage cable for new energy automobile, including insulation core 1, weaving layer 2, band layer 3 and restrictive coating 4; weaving layer 2 cladding is in the insulation core 1 outside, and band layer 3 cladding is in the weaving layer 2 outsides, and restrictive coating 4 cladding is in the band layer 3 outsides. The utility model discloses a set up band layer 3 between weaving layer 2 and restrictive coating 4 at the braid, can effectively avoid weaving the burr and pierce through the sheath, produce the spark breakdown.
The insulated wire core 1 comprises an aluminum alloy conductor 11 and an insulating layer 12, and the insulating layer 12 is coated on the outer side of the conductor 11.
Furthermore, the conductor 11 is formed by twisting a plurality of 8030 aluminum alloy wires with the diameter of 0.1-0.5 mm. The 8030 aluminum alloy conductor has the characteristics of excellent creep resistance, long service life, low cost, high mechanical strength, high elongation, small resistivity, light weight, excellent corrosion resistance, good bending property and the like. The diameter of the conductor monofilament is too large, and the softness of the conductor after wire bundling and compound twisting is poor; the diameter of the conductor monofilament is too small, the monofilament is easy to break in the production process, and the production difficulty is high. Through multiple tests, the inventor finds that the 8030 aluminum alloy monofilament with the thickness of 0.3mm is low in production difficulty, high in conductor softness and excellent in performance.
Furthermore, the number of the 8030 aluminum alloy wires is 100-500.
In one embodiment, the conductor 11 is composed of 238 8030 aluminum alloy wires with the diameter of 0.3mm, the equal share is 7 strands, the twisting is carried out in a reverse twisting mode, the strand pitch is 37-43mm, the strand direction is in the left direction, the compound twisting pitch is 80-90mm, the compound twisting direction is in the right direction, and the section of the conductor is 14.9mm2-16.1mm2. The conductor obtained by the method has good flexibility, the conductor twisting direction is the same as the cabling direction, the cable is endowed with excellent flexibility, and a user hardly feels the existence of internal stress of the cable in the process of charging and using the cable.
Further, the insulating layer 12 is a high and low temperature resistant, environment-friendly, halogen-free and flame retardant TPE insulating layer, and has the advantages of environmental protection, excellent insulating property, high flexibility, good weather resistance, oil resistance, chemical reagent resistance, aging resistance, low temperature resistance of-40 ℃, high temperature resistance of 150 ℃ and the like.
Furthermore, the thickness of the insulating layer 12 is 0.8 to 1.2 mm. The cable can be better protected and the service life can be prolonged by adopting the thick-wall insulating layer; meanwhile, the heat deformation resistance, the chemical stability resistance and the solvent resistance of the cable are improved, the cold flow property is reduced, and the environmental stress cracking resistance, the heat aging resistance and the insulating property are enhanced; the long-term working temperature of the cable can reach 150 ℃, the voltage resistance of the cable can reach 1500V, the current-carrying capacity and short circuit bearing capacity of the cable are improved, and the short-time bearing capacity temperature of the cable can reach 250 ℃. The electric field between the conductor layer core wire of the high-voltage cable and the metal net is densely distributed, if a thin-wall insulating layer is adopted, when air exists between the cable and the high-voltage plug or the high-voltage cable is repaired and processed, the insulating layer 12 is scratched, the insulating layer of the cable is easy to break down, and the service life of the cable is shortened.
In one embodiment, the thickness of the insulating layer 12 is 1mm, and the insulating layer 12 is wrapped outside the conductor 11 by extrusion.
Further, the braid 2 is a tinned copper wire. Furthermore, the weaving density of the weaving layer is more than or equal to 85%, and the diameter of the tin-plated copper single wire is 0.1-0.15 mm. The tin-plated copper single wire shielding is adopted, and the advantages of good heat dissipation effect, good conductivity and the like are achieved.
In a specific embodiment, the diameter of the tin-plated copper single wire is 0.12mm, and the braided layer 2 is wrapped outside the insulated wire core 1 in a wrapping mode.
Further, the wrapping layer 3 is an aluminum foil wrapping tape; furthermore, the thickness of the aluminum foil wrapping tape is 0.02-0.05 mm. The utility model discloses a wrap up the aluminium foil outside tin-plated copper weaving layer, avoid directly crowded package outside weaving layer, can strengthen shielding, electromagnetic interference resistance performance simultaneously, improve the electric conductivity.
In one embodiment, the thickness of the aluminum foil tape is 0.03mm, and the tape layer 3 is wrapped on the outer side of the woven layer 2 in a wrapping mode.
Further, the sheath layer 4 is a high-low temperature resistant environment-friendly halogen-free flame retardant TPE outer sheath which has the hardness of 70-80A and can pass a VW-1 flame retardant test, and has the advantages of environmental protection, excellent insulating property, high flexibility, good weather resistance, oil resistance, chemical reagent resistance, aging resistance, low temperature resistance of-40 ℃, high temperature resistance of 150 ℃ and the like. The thickness of sheath layer 4 is 1.3 ~ 1.8 mm.
Further, the sheath layer 4 includes an inner sheath layer 41 and an outer sheath layer 42, the inner sheath layer covers the belting layer 3, and the outer sheath layer 42 covers the inner sheath layer 41. The thickness of the inner sheath layer 41 is 0.5mm-0.8mm, and the thickness of the outer sheath layer 42 is 0.8mm-1.0 mm. The utility model adopts a double-layer thick-wall sheath, the inner sheath layer 41 is a protective covering layer wrapped on the belting layer 3, which is used for preventing the insulating layer from being affected with damp, mechanical damage, light and chemical aggressive media and the like, and short-circuit current can flow through the insulating layer; the outer sheath layer 42 is a protective covering layer covering the cable inner sheath layer 41, and mainly plays a role in mechanical reinforcement and corrosion prevention. When the outer sheath 42 is extruded, the preheater is arranged outside the inner sheath 41, so that the inner sheath 41 and the outer sheath 42 can be bonded more tightly, a cable can be better protected, and the service life is prolonged; meanwhile, the heat deformation resistance, the chemical stability resistance and the solvent resistance of the cable are improved, the cold flow property is reduced, and the environmental stress cracking resistance, the heat aging resistance and the insulating property are enhanced; the long-term working temperature of the cable can reach 150 ℃, the voltage resistance of the cable can reach 1500V, the current-carrying capacity and short circuit bearing capacity of the cable are improved, and the short-time bearing capacity temperature of the cable can reach 250 ℃. If a single-layer thin-wall sheath layer is adopted, the cable can be corroded by an external medium due to long-time operation, the insulation level and the mechanical level of the thinnest point are reduced, the service life of the cable is influenced, the cable sheath is easily damaged under the action of external normal destructive force, the related performance of the cable is greatly reduced, and the cable can not be protected. Meanwhile, compared with the single-layer thick-wall sheath, the double-layer thick-wall sheath provided by the invention can enable a cable finished product to be softer.
In one embodiment, the inner sheath 41 is wrapped around the wrapping layer 3 by extrusion, and the outer sheath 42 is wrapped around the inner sheath 41 by extrusion.
Compared with the prior art, the utility model has the advantages of it is following and beneficial effect:
(1) light in weight, with low costs: the utility model discloses car high tension cable has adopted the aluminum alloy conductor, compares with traditional copper conductor, under the condition that satisfies the same current-carrying capacity, even enlarge two specifications after, aluminum alloy conductor weight still can reduce 50%; the flexibility is good, and the softness of the wiring harness is improved through the heat treatment process and the structural design; the corrosion resistance is good, and the oxidation and corrosion resistance is 10-100 times that of a copper core cable; the cost is low, and the cost of the aluminum alloy conductor is only 35-50% of that of the copper conductor under the condition of meeting the same current-carrying capacity.
(2) The shielding effect is good: the utility model discloses car high tension cable adopts the tinned copper wire to weave with the shielding of aluminium foil band, and the aluminium foil parcel is outside the braided layer, and reinforcing shielding, electromagnetic interference resistance can improve the electric conductivity, from extension cable life on the other one hand.
(3) High and low temperature resistance: the utility model discloses car high tension cable, thick wall insulating layer and oversheath adopt high low temperature resistant, the halogen-free fire-retardant TPE of environment-friendly, low temperature resistant-40 ℃, high temperature resistant 150 ℃, have improved car high tension cable's high low temperature resistant, weather resistance, heat distortion resistance, heat aging resistance, current-carrying capacity and short circuit withstand temperature.
(4) The cable has high current-carrying capacity and short circuit bearing capacity: the utility model discloses an insulating, the two restrictive coatings of thick wall has improved the bearing capacity of cable current-carrying capacity and short circuit.
(5) Flexibility: the aluminum alloy cable has extremely good bending performance. Aluminum alloy metals have an initial flexibility that is about 30% higher than copper, but a rebound resilience that is 40% lower than copper. The bending radius of a common copper core cable is about 10-20 times of the outer diameter, while the bending radius of an aluminum alloy cable is only 7 times of the outer diameter, so that the cable is more flexible. The utility model discloses car high tension cable adopts many diameters to be 0.3 mm's 8030 aluminum alloy conductor, and bending property is good, can bear a lot of and buckle, has eliminated in the past because of the difficult problem of cable too hard installation, has greatly improved the production efficiency of car in whole car equipment process.
The above description of the present invention does not limit the scope of the present invention. Any other corresponding changes and modifications made according to the technical idea of the present invention should be included in the scope of the claims of the present invention.

Claims (10)

1. A thick-wall aluminum alloy core high-voltage cable for a new energy automobile is characterized by comprising an insulating wire core, a braided layer, a belting layer and a sheath layer;
the braided layer is coated on the outer side of the insulated wire core, the belting layer is coated on the outer side of the braided layer, and the sheath layer is coated on the outer side of the belting layer;
the sheath layer comprises an inner sheath layer and an outer sheath layer, the inner sheath layer is coated on the outer side of the belting layer, and the outer sheath layer is coated on the outer side of the inner sheath layer.
2. The thick-wall aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 1, wherein the insulated wire core comprises an aluminum alloy conductor and an insulating layer, and the insulating layer is coated outside the conductor.
3. The thick-wall aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 2, wherein the conductor is formed by stranding a plurality of 8030 aluminum alloy wires with the diameter of 0.1-0.5 mm.
4. The thick-wall aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 3, wherein the conductor is composed of 238 8030 aluminum alloy wires with the diameter of 0.3mm, the conductor is divided into 7 strands, the 7 strands are twisted in a reverse twisting mode, the pitch of the strands is 37-43mm, the direction of the strands is in the left direction, the pitch of the compound twisting is 80-90mm, the direction of the compound twisting is in the right direction, and the section of the conductor is 14.9mm2-16.1mm2
5. The thick-wall aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 2, wherein the insulating layer is an environment-friendly halogen-free flame-retardant TPE insulating layer with low temperature resistance of-40 ℃ and high temperature resistance of 150 ℃.
6. The thick-walled aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 5, wherein the thickness of the insulating layer is 0.8-1.2 mm.
7. The thick-walled aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 1, wherein the braid is a tinned copper wire.
8. The thick-walled aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 1, wherein the tape layer is an aluminum foil tape.
9. The thick-wall aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 1, wherein the sheath layer is an environmentally-friendly halogen-free flame-retardant TPE outer sheath which has a hardness of 70-80A and can pass a VW-1 flame-retardant test and has a low temperature resistance of-40 ℃ and a high temperature resistance of 150 ℃.
10. The thick-walled aluminum alloy core high-voltage cable for the new energy automobile as claimed in claim 9, wherein the thickness of the inner sheath layer is 0.5mm to 0.8mm, and the thickness of the outer sheath layer is 0.8mm to 1.0 mm.
CN202121449748.1U 2021-06-28 2021-06-28 Thick wall aluminum alloy core high tension cable for new energy automobile Active CN214956126U (en)

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Application Number Priority Date Filing Date Title
CN202121449748.1U CN214956126U (en) 2021-06-28 2021-06-28 Thick wall aluminum alloy core high tension cable for new energy automobile

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202121449748.1U CN214956126U (en) 2021-06-28 2021-06-28 Thick wall aluminum alloy core high tension cable for new energy automobile

Publications (1)

Publication Number Publication Date
CN214956126U true CN214956126U (en) 2021-11-30

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Application Number Title Priority Date Filing Date
CN202121449748.1U Active CN214956126U (en) 2021-06-28 2021-06-28 Thick wall aluminum alloy core high tension cable for new energy automobile

Country Status (1)

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CN (1) CN214956126U (en)

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