CN219286825U - 一种充电线束 - Google Patents
一种充电线束 Download PDFInfo
- Publication number
- CN219286825U CN219286825U CN202222574274.4U CN202222574274U CN219286825U CN 219286825 U CN219286825 U CN 219286825U CN 202222574274 U CN202222574274 U CN 202222574274U CN 219286825 U CN219286825 U CN 219286825U
- Authority
- CN
- China
- Prior art keywords
- copper
- aluminum
- exposed
- harness
- copper cable
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 143
- 229910052802 copper Inorganic materials 0.000 claims abstract description 100
- 239000010949 copper Substances 0.000 claims abstract description 100
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 84
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 84
- 238000009413 insulation Methods 0.000 claims abstract description 8
- 239000010410 layer Substances 0.000 claims description 95
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims description 18
- 239000007787 solid Substances 0.000 claims description 18
- 239000011888 foil Substances 0.000 claims description 16
- 239000011241 protective layer Substances 0.000 claims description 4
- 239000005030 aluminium foil Substances 0.000 claims description 3
- 239000004411 aluminium Substances 0.000 claims description 2
- 238000000034 method Methods 0.000 abstract description 5
- 238000013461 design Methods 0.000 abstract description 3
- 238000003466 welding Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 241000156302 Porcine hemagglutinating encephalomyelitis virus Species 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 239000004703 cross-linked polyethylene Substances 0.000 description 1
- 229920003020 cross-linked polyethylene Polymers 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
- H01R4/625—Soldered or welded connections
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/0207—Wire harnesses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/0207—Wire harnesses
- B60R16/0215—Protecting, fastening and routing means therefor
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
- H01R13/629—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances
- H01R13/631—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances for engagement only
- H01R13/6315—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances for engagement only allowing relative movement between coupling parts, e.g. floating connection
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R31/00—Coupling parts supported only by co-operation with counterpart
- H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/70—Insulation of connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/08—Flat or ribbon cables
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Insulated Conductors (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
- Electric Propulsion And Braking For Vehicles (AREA)
- Electric Cable Arrangement Between Relatively Moving Parts (AREA)
Abstract
本实用新型涉及一种充电线束,包括:由多个铝排构成的导电段;连接于铝排的第一端的充电座连接器;连接于铝排的第二端的电池连接器;充电座连接器的尾端接出铜线缆,铜线缆的末端和铝排的第一端焊接;电池连接器的尾端接出铜线缆,铜线缆的末端和铝排的第二端焊接。与现有技术相比,本实用新型使用铝排代替铜线缆,可节省车内空间,减轻重量和降低成本,可普遍适用于新能源汽车;设计了铝排和铜线缆的连接方式,进行了绝缘、屏蔽和防水设计,工艺简单,成本较低。
Description
技术领域
本实用新型涉及汽车技术领域,尤其是涉及一种用于将电力从汽车的充电插座传递到电池组的充电线束。
背景技术
以纯电动车(EV)和插电式混合动力车(PHEV)为代表的新能源车正取代传统的燃油车。此类新能源通常在底盘搭载电池组(电池包),并且用适于大电流传输的线束/线缆将电力从充电插座传递给电池组。
有屏蔽要求的快速充电线束的常见设计是使用高压屏蔽铜导线。如图1所示,铜导线100的两端连接充电座连接器110和电池连接器120,充电座连接器110用于和外部的充电插头(未示出)连接,电池连接器120用于和电池组或电池组的配电盒连接,多根铜导线100用于传递电力。
充电座连接器110一般被设于车身侧面,例如车身左后或右后,靠近后轮的位置。电池组则通常被设于车身底盘上。因此,充电座连接器和电池组之间的铜导线有较大的长度。由于铜是一种密度较大的材料,且成本亦较高,因此图1所示的线束中,铜导线100的重量和制造成本均会影响新能源汽车降本减重的开发需求。
因此,有必要对新能源车的充电线束进行改进,提供性能稳定的充电线束,满足新能源汽车降本减重的开发需求。
实用新型内容
本实用新型的目的就是为了克服上述现有技术存在的缺陷而提供一种充电线束。
本实用新型的目的可以通过以下技术方案来实现:
一种充电线束,包括:
由多个铝排构成的导电段;
连接于所述铝排的第一端的充电座连接器;
连接于所述铝排的第二端的电池连接器。
进一步地,所述充电座连接器的尾端接出铜线缆,所述铜线缆的末端和所述铝排的第一端焊接。
进一步地,所述电池连接器的尾端接出铜线缆,所述铜线缆的末端和所述铝排的第二端焊接。
进一步地,所述铜线缆自内到外包括铜线芯、铜缆绝缘层、铜缆屏蔽层、铝箔和护套,在铜线缆与铝排的连接处,一段所述铜缆屏蔽层裸露在铝箔外形成外露铜缆屏蔽层,一段所述铜缆绝缘层裸露在外露铜缆屏蔽层外形成外露铜缆绝缘层,一段所述铜线芯裸露在所述外露铜缆绝缘层外形成外露铜线芯,所述外露铜线芯被设置为扁平铜端子;
所述铝排自内到外包括扁平实心铝芯、线束绝缘层、线束屏蔽层和保护层,在铜线缆与铝排的连接处,一段所述线束绝缘层裸露在线束屏蔽层外形成外露线束绝缘层,一段所述扁平实心铝芯裸露在外露线束绝缘层外形成外露扁平实心铝芯,所述外露扁平实心铝芯作为扁平铝端子;
所述扁平铜端子和扁平铝端子焊接连接。
进一步地,在扁平铜端子和扁平铝端子的焊接互连部分外包覆有第一热缩管,所述第一热缩管包覆的区域还包括焊接互连部分两端的外露铜缆绝缘层和外露线束绝缘层。
进一步地,在所述第一热缩管外包覆有编织屏蔽层,所述编织屏蔽层包覆的区域还包括整个铝排的线束屏蔽层和第一热缩管一端的一段铜缆屏蔽层,所述编织屏蔽层与第一热缩管一端的铜缆屏蔽层在一段距离内产生交叠。
进一步地,编织屏蔽层与第一热缩管一端的铜缆屏蔽层的交叠区域上缠绕有铝箔带。
进一步地,编织屏蔽层与第一热缩管一端的铜缆屏蔽层的交叠区域上压接有铜环端子。
进一步地,在铜线缆与铝排的连接处,所述编织屏蔽层外还包覆有第二热缩管,所述第二热缩管的一端还包覆铜线缆的一段所述护套。
进一步地,所述铝箔包覆在铜缆绝缘层或铜缆屏蔽层外。
与现有技术相比,本实用新型具有以下有益效果:
在充电线束中,使用铝排代替铜线缆,可节省车内空间,减轻重量和降低成本,可普遍适用于新能源汽车。考虑到充电座连接器和电池连接器的尾端使用铜线缆,设计了铝排和铜线缆之间的连接方案,设计的连接方案工艺简单,成本较低,可实现较好的屏蔽效果和防水密封效果。
附图说明
图1为现有技术中充电线束的结构示意图;
图2为本实用新型中线束的结构示意图;
图3为铜线缆的结构示意图;
图4为铝排的结构示意图;
图5为铝排和铜线缆的连接结构示意图:焊接连接;
图6为铝排和铜线缆的连接结构示意图:包覆第一热缩管;
图7为铝排和铜线缆的连接结构示意图:包覆编织屏蔽层;
图8为铝排和铜线缆的连接结构示意图:缠绕铝箔带;
图9为铝排和铜线缆的连接结构示意图:包覆第二热缩管;
附图标记:100、铜导线,110、充电座连接器,120、电池连接器;
1、铝排,2、充电座连接器,3、电池连接器,4、铜线缆,5、焊接互连部分,6、第一热缩管,7、编织屏蔽层,8、铝箔带,9、第二热缩管;
1-1、扁平实心铝芯,1-2、线束绝缘层,1-3、线束屏蔽层,1-4、保护层;
4-1、铜线芯,4-2、铜缆绝缘层,4-3、铜缆屏蔽层,4-4、铝箔,4-5、护套。
具体实施方式
下面结合附图和具体实施例对本实用新型进行详细说明。本实施例以本实用新型技术方案为前提进行实施,给出了详细的实施方式和具体的操作过程,但本实用新型的保护范围不限于下述的实施例。
在附图中,结构相同的部件以相同数字标号表示,各处结构或功能相似的组件以相似数字标号表示。附图所示的每一组件的尺寸和厚度是任意示出的,本实用新型并没有限定每个组件的尺寸和厚度。为了使图示更清晰,附图中有些地方适当夸大了部件。
在本申请实施例的描述中,需要理解的是,术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,或者是该申请产品使用时惯常摆放的方位或位置关系,或者是本领域技术人员惯常理解的方位或位置关系,仅是为了便于描述本申请和简化描述,而不是指示或暗示所指的设备或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本申请的限制。
此外,术语“第一”、“第二”、“第三”等仅用于区分描述,而不能理解为指示或暗示相对重要性。
在本申请实施例的描述中,还需要说明的是,除非另有明确的规定和限定,术语“设置”、“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本申请中的具体含义。
实施例1:
一种充电线束,如图2所示,包括:由多个铝排1构成的导电段;连接于铝排的第一端的充电座连接器2;连接于铝排的第二端的电池连接器3。充电座连接器2的尾端接出铜线缆4,铜线缆4的末端和铝排1的第一端焊接。电池连接器3的尾端接出铜线缆4,铜线缆4的末端和铝排1的第二端焊接。
其中,充电线束包括两根铝排1,铝排1可以预成形为特定的形状以适应于在车体内的安装。线束两端的充电座连接器2和电池连接器3的尾端仍用铜线缆4接入,然后铝排1的两端和上述两个连接器尾端的铜线缆4中的铜导体形成电连接,从而完成从充电插座到电池组/电池组配线盒的电传输路径。
如图3所示,本实施例中,铜线缆4从内到外,依次包括铜线芯4-1、铜缆绝缘层4-2、铜缆屏蔽层4-3、铝箔4-4和护套4-5。可以理解的是,铝箔4-4可以设置在铜缆屏蔽层4-3外侧,作为一种替代,其也可以在铜缆屏蔽层4-3的内侧。
如图4所示,本实施例中,铝排1包括扁平实心铝芯1-1、线束绝缘层1-2、线束屏蔽层1-3和保护层1-4。扁平实心铝芯1-1的横截面积可为120mm2。线束绝缘层1-2可通过PA12、XLPE或PVC材料挤塑。线束屏蔽层1-3可以是编织层、编织套管,或者铝带或铜带的缠绕结构。保护层可以是套管或管道。
关于铝排1和铜线缆4的连接结构,如下:
如图5所示,一段铜缆屏蔽层4-3裸露在铝箔4-4外形成外露铜缆屏蔽层4-3,一段铜缆绝缘层4-2裸露在外露铜缆屏蔽层4-3外形成外露铜缆绝缘层4-2,一段铜线芯4-1裸露在外露铜缆绝缘层4-2外形成外露铜线芯4-1,外露铜线芯4-1被设置为扁平铜端子;在铜线缆4与铝排1的连接处,一段线束绝缘层1-2裸露在线束屏蔽层1-3外形成外露线束绝缘层1-2,一段扁平实心铝芯1-1裸露在外露线束绝缘层1-2外形成外露扁平实心铝芯1-1,外露扁平实心铝芯1-1作为扁平铝端子;扁平铜端子和扁平铝端子焊接连接。
具体操作时,在铜线缆4与铝排1的连接处,将铜线缆4的端部剥开,从而在端部露出一段铜线芯4-1,在铜芯线后一段距离露出一段铜缆绝缘层4-2,在铜缆绝缘层4-2后一段距离露出一段铜缆屏蔽层4-3;同样,将铝排1的端部剥开,从而在端部露出一段扁平实心铝芯1-1,在扁平实心铝芯1-1后一段距离露出一段线束绝缘层1-2,在线束绝缘层1-2后一段距离露出一段线束屏蔽层1-3;将外露的铜线芯4-1加工制作为扁平铜端子,将外露的扁平实心铝芯1-1加工制作为扁平铝端子,扁平铜端子和扁平铝端子以诸如波峰焊的技术焊接连接。
如图6所示,在扁平铜端子和扁平铝端子的焊接互连部分5外包覆有第一热缩管6,第一热缩管6包覆的区域还包括焊接互连部分5两端的外露铜缆绝缘层4-2和外露线束绝缘层1-2。
如图7所示,在第一热缩管6外包覆有编织屏蔽层7,编织屏蔽层7包覆的区域还包括整个铝排1的线束屏蔽层1-3和第一热缩管6一端的铜缆屏蔽层4-3,编织屏蔽层7与第一热缩管6一端的铜缆屏蔽层4-3在一段距离内产生交叠。
如图8所示,本实施例中,在编织屏蔽层7与第一热缩管6一端的铜缆屏蔽层4-3的交叠区域上缠绕有铝箔带8。其他实施方式中,作为一种替代方式,不使用铝箔带8,而是在编织屏蔽层7与第一热缩管6一端的铜缆屏蔽层4-3的交叠区域上压接有铜环端子。
如图9所示,本实施例中,在铜线缆4与铝排1的连接处,编织屏蔽层7外还包覆有第二热缩管9,第二热缩管9的一端还包覆铜线缆4的一段护套4-5。此外,上文所提到的铝箔带8为铝箔胶带,铝箔胶带的一面带铝箔,用于和编织屏蔽层7接触,另一面涂胶,用于和第二热缩管9接触。
为了减重降本,在充电线束中,可以使用铝排1代替铜线缆4,可节省车内空间,减轻重量和降低成本,可普遍适用于新能源汽车。
考虑到充电座连接器2和电池连接器3的尾端使用铜线缆4,本申请设计了铝排1和铜线缆4之间的连接方案,如下:
扁平实心铝芯1-1和锻压成扁平后的铜线芯4-1焊接,套热缩管做绝缘层,编织屏蔽层覆盖整个铝排1,并与铜缆屏蔽层4-3有一个接触重叠区,在重叠区缠绕胶带或压接铜端子,从而实现编织屏蔽层与铝排1和铜缆屏蔽层4-3连接,最后再套热缩管进行密封防水。本申请设计的连接方案工艺简单,成本较低。
以上详细描述了本实用新型的较佳具体实施例。应当理解,本领域的普通技术人员无需创造性劳动就可以根据本实用新型的构思做出诸多修改和变化。因此,凡本技术领域中技术人员依本实用新型的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案,皆应在由权利要求书所确定的保护范围内。
Claims (7)
1.一种充电线束,其特征在于,包括:
由多个铝排构成的导电段;
连接于所述铝排的第一端的充电座连接器;
连接于所述铝排的第二端的电池连接器;
所述充电座连接器的尾端接出铜线缆,所述铜线缆的末端和所述铝排的第一端焊接;
所述电池连接器的尾端接出铜线缆,所述铜线缆的末端和所述铝排的第二端焊接;
所述铜线缆自内到外包括铜线芯、铜缆绝缘层、铜缆屏蔽层、铝箔和护套,在铜线缆与铝排的连接处,一段所述铜缆屏蔽层裸露在铝箔外形成外露铜缆屏蔽层,一段所述铜缆绝缘层裸露在外露铜缆屏蔽层外形成外露铜缆绝缘层,一段所述铜线芯裸露在所述外露铜缆绝缘层外形成外露铜线芯,所述外露铜线芯被设置为扁平铜端子;
所述铝排自内到外包括扁平实心铝芯、线束绝缘层、线束屏蔽层和保护层,在铜线缆与铝排的连接处,一段所述线束绝缘层裸露在线束屏蔽层外形成外露线束绝缘层,一段所述扁平实心铝芯裸露在外露线束绝缘层外形成外露扁平实心铝芯,所述外露扁平实心铝芯作为扁平铝端子;
所述扁平铜端子和扁平铝端子焊接连接。
2.根据权利要求1所述的一种充电线束,其特征在于,在扁平铜端子和扁平铝端子的焊接互连部分外包覆有第一热缩管,所述第一热缩管包覆的区域还包括焊接互连部分两端的外露铜缆绝缘层和外露线束绝缘层。
3.根据权利要求2所述的一种充电线束,其特征在于,在所述第一热缩管外包覆有编织屏蔽层,所述编织屏蔽层包覆的区域还包括整个铝排的线束屏蔽层和第一热缩管一端的一段铜缆屏蔽层,所述编织屏蔽层与第一热缩管一端的铜缆屏蔽层在一段距离内产生交叠。
4.根据权利要求3所述的一种充电线束,其特征在于,编织屏蔽层与第一热缩管一端的铜缆屏蔽层的交叠区域上缠绕有铝箔带。
5.根据权利要求3所述的一种充电线束,其特征在于,编织屏蔽层与第一热缩管一端的铜缆屏蔽层的交叠区域上压接有铜环端子。
6.根据权利要求3所述的一种充电线束,其特征在于,在铜线缆与铝排的连接处,所述编织屏蔽层外还包覆有第二热缩管,所述第二热缩管的一端还包覆铜线缆的一段所述护套。
7.根据权利要求1所述的一种充电线束,其特征在于,所述铝箔包覆在铜缆绝缘层或铜缆屏蔽层外。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202210963685 | 2022-08-11 | ||
CN2022109636854 | 2022-08-11 |
Publications (1)
Publication Number | Publication Date |
---|---|
CN219286825U true CN219286825U (zh) | 2023-06-30 |
Family
ID=83523917
Family Applications (6)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202222179171.8U Active CN218123916U (zh) | 2022-08-11 | 2022-08-18 | 用于新能源车的汽车线束 |
CN202210993064.0A Pending CN115189196A (zh) | 2022-08-11 | 2022-08-18 | 汽车充电线束 |
CN202222219961.4U Active CN217956323U (zh) | 2022-08-11 | 2022-08-23 | 铝质汽车充电线束 |
CN202222574274.4U Active CN219286825U (zh) | 2022-08-11 | 2022-09-27 | 一种充电线束 |
CN202222564712.9U Active CN219286824U (zh) | 2022-08-11 | 2022-09-27 | 一种充电线束 |
CN202310789012.6A Pending CN117594994A (zh) | 2022-08-11 | 2023-06-29 | 带有柔性连接段的汽车线束 |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202222179171.8U Active CN218123916U (zh) | 2022-08-11 | 2022-08-18 | 用于新能源车的汽车线束 |
CN202210993064.0A Pending CN115189196A (zh) | 2022-08-11 | 2022-08-18 | 汽车充电线束 |
CN202222219961.4U Active CN217956323U (zh) | 2022-08-11 | 2022-08-23 | 铝质汽车充电线束 |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202222564712.9U Active CN219286824U (zh) | 2022-08-11 | 2022-09-27 | 一种充电线束 |
CN202310789012.6A Pending CN117594994A (zh) | 2022-08-11 | 2023-06-29 | 带有柔性连接段的汽车线束 |
Country Status (3)
Country | Link |
---|---|
US (1) | US20240051478A1 (zh) |
EP (1) | EP4321389A1 (zh) |
CN (6) | CN218123916U (zh) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN118609887A (zh) * | 2024-08-09 | 2024-09-06 | 昆山康耐盛电子科技有限公司 | 一种具有屏蔽功能的新能源汽车旋变定子线束及其制备工艺 |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN117673794B (zh) * | 2023-11-28 | 2024-09-13 | 鹤壁天海环球电器有限公司 | 一种高压铝棒转接线束及其制造设备和制造方法 |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP5740146B2 (ja) * | 2010-12-10 | 2015-06-24 | 矢崎総業株式会社 | ワイヤハーネス |
US20200144579A1 (en) * | 2018-11-01 | 2020-05-07 | Ford Global Technologies, Llc | Electrified vehicle with low profile busbar for high current interfaces, and corresponding method |
JP7123514B2 (ja) * | 2020-06-17 | 2022-08-23 | 矢崎総業株式会社 | 導電構造体 |
CN114566309A (zh) * | 2022-03-07 | 2022-05-31 | 广州小鹏汽车科技有限公司 | 线缆、电能传输系统和车辆 |
-
2022
- 2022-08-18 CN CN202222179171.8U patent/CN218123916U/zh active Active
- 2022-08-18 CN CN202210993064.0A patent/CN115189196A/zh active Pending
- 2022-08-23 CN CN202222219961.4U patent/CN217956323U/zh active Active
- 2022-09-27 CN CN202222574274.4U patent/CN219286825U/zh active Active
- 2022-09-27 CN CN202222564712.9U patent/CN219286824U/zh active Active
-
2023
- 2023-06-29 CN CN202310789012.6A patent/CN117594994A/zh active Pending
- 2023-08-04 US US18/230,258 patent/US20240051478A1/en active Pending
- 2023-08-07 EP EP23190102.6A patent/EP4321389A1/en active Pending
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN118609887A (zh) * | 2024-08-09 | 2024-09-06 | 昆山康耐盛电子科技有限公司 | 一种具有屏蔽功能的新能源汽车旋变定子线束及其制备工艺 |
Also Published As
Publication number | Publication date |
---|---|
EP4321389A1 (en) | 2024-02-14 |
CN115189196A (zh) | 2022-10-14 |
US20240051478A1 (en) | 2024-02-15 |
CN219286824U (zh) | 2023-06-30 |
CN117594994A (zh) | 2024-02-23 |
CN217956323U (zh) | 2022-12-02 |
CN218123916U (zh) | 2022-12-23 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN219286825U (zh) | 一种充电线束 | |
EP2533252B1 (en) | Wire harness | |
US9623815B2 (en) | Wire harness with exterior member | |
US9502153B2 (en) | Wire harness with coaxial composite conductive path | |
CN103958278B (zh) | 高压导电线及线束 | |
CN104024055A (zh) | 线束中间构件和线束 | |
US9252575B2 (en) | High-voltage conduction path and wiring harness | |
CN104737399A (zh) | 线束外装部件和线束 | |
US10014642B2 (en) | Method for manufacturing wire harness | |
CN209217310U (zh) | 一种充电连接设备及充电系统 | |
KR102428491B1 (ko) | 차량용 고전압 코어 전선 연결장치 | |
CN109449667A (zh) | 一种充电连接设备及充电系统 | |
CN218334451U (zh) | 一种逆变器用防水连接线 | |
CN220021827U (zh) | 一种高压线束屏蔽结构 | |
CN219436288U (zh) | 一种用于电动汽车电传导硬母排的屏蔽连接系统 | |
CN221305190U (zh) | 一种一体化注塑高压线束总成 | |
US20230040692A1 (en) | Wire harness | |
CN220114458U (zh) | 充电线缆、充电枪及充电系统 | |
CN221806040U (zh) | 电能分配装置及用电装置 | |
CN219626343U (zh) | 导线、线束以及电池包 | |
CN217134016U (zh) | 线缆、充电枪及充电桩 | |
CN114026659A (zh) | 电动车辆或混合动力车辆的快速充电设备 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
GR01 | Patent grant | ||
GR01 | Patent grant |