CN218414006U - Vibration-resistant high-voltage shielded cable - Google Patents

Abstract

The present disclosure provides a vibration resistant high voltage shielded cable. 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 disclosure can reduce the possibility of stress fracture of the braid and increase the tensile property and the shielding property of the shielded cable.

Description

Vibration-resistant high-voltage shielded cable

Technical Field

The present disclosure relates to the field of cables, and more particularly, to a cable with 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. And the high-voltage wire harness is used as a medium for mutually associating all components in the high-voltage system, and has important effect and influence on the safety of the new energy automobile. Therefore, it is an important requirement of new energy vehicles to improve the self-capability (e.g., 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 sections, other special requirements than the above conventional performance requirements are also created for high voltage cables. 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 an improvement of the existing high voltage shielded cable to improve the performance of the high voltage shielded cable.

SUMMERY OF THE UTILITY MODEL

The utility model provides a technical scheme aims at solving among the prior art shielded cable's performance and remains to promote and/or shielded cable easily takes place conductor and/or the cracked problem of shielding layer under high-frequency vibration and tensile operating mode.

In an aspect of the present invention, there is provided a shielded cable, the shielded cable includes from inside to outside in sequence: a conductor part; an insulating layer; a shield layer, the shield layer comprising: a metal layer; and a woven 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 constitute a composite layer.

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

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

In at least one embodiment of one aspect of the present invention, the conductor portion includes at least one of a copper foil wire and an aramid wire and a copper wire, and the copper wire is twisted together with the at least one of the copper foil wire and the aramid wire.

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 present invention, the braid is braided from a tinned copper wire.

Compared with the prior art, the utility model discloses can have following one or more advantage:

(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) By arranging the composite layer in the shielding layer between the insulating layer and the braid layer, the composite layer can be coated outside the insulating layer, and the braid layer can be coated outside the composite layer, so that the manufacturing procedures of the shielding cable are reduced, and the cost for manufacturing the shielding cable is reduced.

(3) Through arranging the metal layer 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 that 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 properties.

(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 small-pitch stranded copper wires, copper foil wires and aramid fibers, and the softness of the conductor part can be improved, so that the bending resistance of the conductor part can be improved.

Drawings

To further clarify the above and other advantages and features of various embodiments of the present invention, a more particular description of various 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.

Fig. 1 shows a schematic cross-sectional view of a shielded electrical cable according to an 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 present invention.

Fig. 3 is a flowchart illustrating a process of covering a shielding layer outside an insulating layer in a method of manufacturing a shielded cable according to an embodiment of the present invention.

Detailed Description

The present invention will be further described with reference to the following embodiments and drawings, and more details will be set forth in the following description in order to provide a thorough understanding of the present invention, but it is obvious that the present invention can be implemented in various other ways different from those described herein, and those skilled in the art can similarly popularize and deduce the present invention according to the actual application without departing from the spirit of the present invention, and therefore, the scope of the present invention should not be limited by the contents of the embodiments.

This application uses specific language 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 throughout this specification are not necessarily all referring to the same embodiment. Furthermore, some features, structures, or characteristics of one or more embodiments of the present application may be combined as appropriate.

It should be noted that in the following description of embodiments of the present application, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure aiding in the understanding of one or more of the embodiments. This method of disclosure, however, is not intended to imply that more features are required 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 an 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 filaments 13 may include copper foil and synthetic fibers (e.g., aramid filaments, polyester filaments, nylon filaments, 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 braid 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 by 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 utility model discloses a design composite bed 31 into two metal levels (for example, the aluminium lamination) and place composite bed 31 between insulating layer 21 and weaving layer 33, can show the shielding performance who improves shielded cable 1, including surface transfer impedance performance and shielding decay performance.

Referring to fig. 1, shielded electrical cable 1 may further include a jacket layer 41, and jacket layer 41 may be positioned about an outer surface of braid 33 and adjacent 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 chart of a method 200 for manufacturing a shielded electrical cable (hereinafter referred to as method 200) according to an embodiment of the present invention. It is to be understood that the shielded cable manufacturing method itself does not constitute a protective body of the utility model, but the description of the shielded cable manufacturing method will be useful for understanding the relevant structure of the shielded cable 1. 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 twisting 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 coated 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 a plastic layer and a metal layer, and the braid 33 may be braided from a tinned copper wire (e.g., an electroplated tinned copper wire, a hot-plated tinned copper wire).

Referring to fig. 3, fig. 3 is a flow chart illustrating a process of covering 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 braided on the outer surface of the composite layer 31 (or the metal layer) by a precise braiding process, or the braided layer 33 formed by braiding in advance 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".

The utility model discloses a design composite bed 31 (or metal level) and be located between insulating layer 21 and weaving layer 33, can allow when utilizing to indulge package technology with composite bed 31 (or metal level) cladding outside insulating layer 21, with weaving layer 33 cladding outside composite bed 31 (or metal level) (for example, utilize the surface that the precision weaving technology weaved the tinned copper wire at composite bed 31 (or metal level)) to can reduce shielded cable 1's manufacturing procedure and reduce the cost of manufacturing 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 (7)

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 braid layer (33).

2. Shielded electrical cable according to claim 1, characterized in that the shielding layer further comprises a plastic layer, the metal layer being located between the plastic layer and the braid and being immediately adjacent 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. Shielded electrical cable according to any one of claims 1-4, characterized in that the conductor section comprises a copper wire (11) and at least one of a copper foil wire (13) and an aramid wire (15), and in that the copper wire (11) is stranded together with the at least one of the copper foil wire (13) and the aramid wire (15).

6. The shielded cable of claim 5, wherein the diameter of the copper wire is the same as the diameter of the copper foil wire.

7. A shielded electrical cable according to any one of claims 1 to 4, wherein the braid is braided from tinned copper wire.

Images