CN222939681U - A vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles - Google Patents

Abstract

The utility model relates to the technical field of automobile cables, in particular to a vibration-resistant and bending-resistant high-voltage cable suitable for a new energy automobile, which comprises a conductor, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside; the novel insulated single-wire cable is characterized in that the conductor is formed by twisting four layers of strands, the twisting direction of each layer of strands of the conductor is the same as the twisting direction of monofilaments forming the strands, the twisting direction of each layer of strands is the left direction, the strands are completely untwisted to form the conductor according to a normal twisting structure, the conductor and the insulating layer form an insulated single wire together, and the shielding layer is of a double-layer shielding structure arranged on the outer side of the insulated single wire. The ratio of the number of the first layer of strands to the number of the fourth layer of strands is 1:6:12:18, and the ratio of the number of the strands is 9:10:18:19. The four layers of strands have equal diameters. The pitch diameter ratio of the first layer of folded yarn to the fourth layer of folded yarn is respectively 0, 20-22 times, 16-18 times and 13-15 times. The cable solves the problems of high-frequency vibration, poor bending property, heavy weight and the like of the cable for the new energy automobile.

Description

Vibration-resistant bending-resistant high-voltage cable suitable for new energy automobile

Technical Field

The utility model relates to the technical field of automobile cables, in particular to a vibration-resistant and bending-resistant high-voltage cable suitable for a new energy automobile.

Background

At present, china has become the largest new energy automobile production base in the world, and related enterprises matched with the new energy automobile production base face huge opportunities and tests. As an important component of the new energy automobile, how to develop a light high-voltage cable with vibration resistance and bending resistance becomes an important subject of a harness manufacturer.

At present, most of new energy automobile high-voltage cables in the market adopt wiring harness solutions in the period of gasoline automobiles, and most of the high-voltage cables adopt copper wires as conductors, so that the weight is high, and the energy consumption of the automobiles is increased. The gasoline car high-voltage structure part connecting device is relatively less, the problem that a terminal or a conductor shakes and falls off is solved, the wiring space is large, the bending radius of a cable is large, and the bending performance test is less when designing the cable. Some automobiles use aluminum conductors as conductors, but because of a large number of automobile connecting devices and large vibration, the automobile high-voltage wire harness often has the problems of conductor monofilament fracture, insulation skin fracture, poor harness bending property, difficult processing and the like when the automobile high-voltage wire harness is used for a long time.

Disclosure of utility model

Aiming at the defects existing in the prior art, the utility model provides a vibration-resistant and bending-resistant light high-voltage cable suitable for a new energy automobile, and the cable solves the problems of high-frequency vibration, poor bending property, heavy weight and the like of the cable for the new energy automobile.

The present utility model has been achieved in such a way that,

The vibration-resistant and bending-resistant high-voltage cable suitable for the new energy automobile comprises a conductor, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside, wherein the conductor is formed by twisting four layers of strands, the twisting direction of each layer of strands of the conductor is the same as the twisting direction of monofilaments forming the strands, and the twisting directions of the strands are all the left directions;

The conductor and the insulating layer jointly form an insulating single wire, the shielding layer is of a double-layer shielding structure arranged on the outer side of the insulating single wire, the number ratio of the first layer of strands to the fourth layer of strands is 1:6:12:18, and the number ratio of the strands is 9:10:18:19.

Further, the four layers of strands have equal diameters.

Further, the pitch diameter ratio of the first layer of strands to the fourth layer of strands is 0, 20-22 times, 16-18 times, 13-15 times respectively.

Further, the thickness of the insulating layer is 0.8-1.2mm.

Further, the shielding layer comprises a braiding layer and a layer of wrapping aluminum-plastic composite belt arranged on the outer side of the braiding layer.

Further, the braiding layers are formed by braiding metal monofilaments in a 2-to-2 mode along the vertical direction.

Furthermore, the metal monofilaments are tinned copper wires, the diameter is not more than 0.20mm, and the knitting density is not less than 85%.

Further, the thickness of the wrapping aluminum-plastic composite belt is 0.025mm, and the wrapping lap rate is not less than 15%.

Further, the sheath layer is extruded silicon rubber arranged on the outer side of the shielding layer, and the thickness of the sheath layer is not less than 1.2mm.

The utility model has the advantages and technical effects that:

The vibration-resistant and bending-resistant light high-voltage cable is suitable for the new energy automobile, the twisting mode and structure of the cable conductor are redesigned by changing the diameter and the material of the single filament of the cable, the shielding of the cable is optimized, and the proper insulation and sheath material is selected, so that the vibration resistance and bending resistance of the cable are improved, the weight of the cable is reduced, the service life of the cable in the new energy automobile is remarkably prolonged, and the energy consumption of the automobile is reduced.

Drawings

FIG. 1 is a schematic cross-sectional view of a high voltage cable of the present utility model;

fig. 2 is a schematic diagram of a four-layer strand distribution of a conductor of the present utility model.

In the figure, 1, a conductor, 11, a first layer of stranded wires, 12, a second layer of stranded wires, 13, a third layer of stranded wires, 14, a fourth layer of stranded wires, 2, an insulating layer, 3, a shielding layer, 31, a braiding layer, 32, a wrapping aluminum-plastic composite belt and 4, a sheath layer.

Detailed Description

The present utility model will be described in further detail with reference to the following examples in order to make the objects, technical solutions and advantages of the present utility model more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the utility model.

The utility model discloses a vibration-resistant and bending-resistant high-voltage cable suitable for a new energy automobile, which is shown in fig. 1, and comprises a conductor 1, an insulating layer 2, a shielding layer 3 and a sheath layer 4 which are sequentially arranged from inside to outside, wherein the conductor is formed by twisting four layers of strands, and the twisting direction of each layer of strands of the conductor is the same as the twisting direction of monofilaments forming the strands, and is left. Specifically, the first layer of strands 11 are used as an intermediate core, the number of the first layer of strands 11 is 1, 9 aluminum monofilaments with the diameter of 0.52mm are subjected to left-hand twisting, the pitch is 44mm, no twisting pitch exists, the number of the second layer of strands 12 wrapped outside the first layer of strands is 6, 10 aluminum monofilaments with the diameter of 0.52mm are subjected to left-hand twisting, the pitch is 45mm, the twisting pitch is 90-110mm, the number of the third layer of strands 13 wrapped outside the second layer of strands is 12, 18 aluminum monofilaments with the diameter of 0.52mm are subjected to left-hand twisting, the pitch is 65mm, the twisting pitch is 155-175mm, the number of the fourth layer of strands 14 wrapped outside the third layer of strands is 18, 19 aluminum monofilaments with the diameter of 0.52mm are subjected to left-hand twisting, the pitch is 66mm, and the twisting pitch is 160-180mm;

Preferably, the strands are further subjected to 100% complete untwisting to form the conductor according to a regular twist 1+6+12+18 structure, so that the twisting tension of monofilaments is eliminated, the pitch diameter ratio of the second-layer strands (the pitch diameter ratio is the twisting pitch of the conductor/the outer diameter of the conductor) is 20-22 times, the pitch diameter ratio of the third-layer strands is 16-18 times, and the pitch diameter ratio of the fourth-layer strands is 13-15 times. The conductor adopts aluminum wires with the diameter of 0.52mm, ensures the uniformity of the monofilaments, further reduces the weight of products and reduces the energy consumption of the whole vehicle.

In the above technical scheme, preferably, the insulating layer 2 material is formed by extruding and wrapping double tetra-silicon sulfide rubber with the temperature resistance grade of 150-200 ℃, the thickness is 0.8-1.2mm, and the insulating layer is vulcanized by infrared high-temperature irradiation. The double-disulfide silicon rubber insulation can effectively improve the flexibility of the cable, ensure that the cable has higher temperature resistance level, and avoid insulation cracking caused by long-time bending of the cable.

The shielding layer 3 is of a double-layer shielding structure arranged on the outer side of an insulating single wire, and specifically comprises a weaving layer 31 and a layer of wrapping aluminum-plastic composite belt 32 arranged on the outer side of the weaving layer 31, wherein the weaving layer 31 is woven by metal monofilaments in a 2-to-2 mode along the vertical direction, in the technical scheme, preferably, the metal monofilaments are tinned copper wires, the diameter requirement is not more than 0.20mm, the weaving density is not less than 85%, the thickness of the aluminum-plastic composite belt is 0.025mm, and the wrapping coverage rate is not less than 15%. The double-layer shielding structure in the technical scheme avoids transmission of external electromagnetic signals into the cable.

The sheath layer 4 is extruded silicon rubber arranged on the outer side of the shielding layer, has the thickness of not less than 1.2mm, is formed by high-temperature irradiation and vulcanization of infrared rays, and is used for protecting the shielding layer and stabilizing the product structure.

In the above technical scheme, preferably, the sheath layer 4 is made of the double tetra-vulcanized silicone rubber, and the silicone rubber sheath is softer than polyolefin materials, is not easy to crack, has a temperature resistance level of up to 200 ℃, and avoids the sheath cracking of the cable caused by high temperature, bending and other factors.

The foregoing description of the preferred embodiments of the utility model is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the utility model.

Claims (9)

1. A vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles, comprising a conductor, an insulating layer, a shielding layer and a sheath layer arranged in sequence from the inside to the outside; characterized in that: the conductor is made of four layers of strands, and the stranding direction of each layer of the conductor strands is the same as the stranding direction of the monofilaments constituting the strands, both of which are left-handed; the strands are 100% fully back-twisted and twisted according to a regular twisting structure to form the conductor; The conductor and the insulating layer together form an insulated single wire; the shielding layer is a double-layer shielding structure arranged outside the insulated single wire; The ratio of the number of strands from the first layer to the fourth layer is 1:6:12:18, and the ratio of the number of strands is 9:10:18:19. 2. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as described in claim 1 is characterized in that the diameters of the four layers of strands are equal. 3. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as described in claim 2 is characterized in that the pitch diameter ratios of the first layer of strands to the fourth layer of strands are 0, 20-22 times, 16-18 times, and 13-15 times, respectively. 4. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as claimed in claim 1, characterized in that the thickness of the insulating layer is 0.8-1.2 mm. 5. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as described in claim 1 is characterized in that the shielding layer includes a braided layer composed of metal monofilaments and a layer of wrapped aluminum-plastic composite tape arranged on the outside of the braided layer. 6. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as claimed in claim 5, characterized in that the braided layer is formed by braiding metal monofilaments in a 2-over-2 manner in a vertical direction. 7. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as described in claim 6 is characterized in that the metal monofilament is a tinned copper wire with a diameter requirement of no more than 0.20 mm and a braiding density of no less than 85%. 8. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as described in claim 5, characterized in that the thickness of the wrapped aluminum-plastic composite tape is 0.025 mm, and the wrapping overlap rate is not less than 15%. 9. The vibration-resistant and bending-resistant high-voltage cable suitable for new energy vehicles as claimed in claim 1, characterized in that the sheath layer is extruded silicone rubber arranged on the outside of the shielding layer, and the thickness is not less than 1.2 mm.