WO2018095177A1 - 一种异形电缆及其制备方法 - Google Patents

一种异形电缆及其制备方法 Download PDF

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Publication number
WO2018095177A1
WO2018095177A1 PCT/CN2017/107577 CN2017107577W WO2018095177A1 WO 2018095177 A1 WO2018095177 A1 WO 2018095177A1 CN 2017107577 W CN2017107577 W CN 2017107577W WO 2018095177 A1 WO2018095177 A1 WO 2018095177A1
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WO
WIPO (PCT)
Prior art keywords
core
cable
shaped
aluminum
segment
Prior art date
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PCT/CN2017/107577
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English (en)
French (fr)
Inventor
王超
Original Assignee
吉林省中赢高科技有限公司
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by 吉林省中赢高科技有限公司 filed Critical 吉林省中赢高科技有限公司
Priority to ES17873218T priority Critical patent/ES2960346T3/es
Priority to CA3044310A priority patent/CA3044310C/en
Priority to PL17873218.6T priority patent/PL3531429T3/pl
Priority to JP2019524227A priority patent/JP7112098B2/ja
Priority to US16/462,246 priority patent/US11361881B2/en
Priority to EP17873218.6A priority patent/EP3531429B1/en
Priority to RS20231055A priority patent/RS64814B1/sr
Priority to MYPI2019002442A priority patent/MY195852A/en
Priority to MX2019005596A priority patent/MX2019005596A/es
Publication of WO2018095177A1 publication Critical patent/WO2018095177A1/zh
Priority to ZA2019/03103A priority patent/ZA201903103B/en

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    • 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
    • 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
    • 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
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or 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
    • H01B7/0009—Details relating to the conductive cores
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/24—Devices affording localised protection against mechanical force or pressure
    • 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
    • H01B7/009—Cables with built-in connecting points or with predetermined areas for making deviations

Definitions

  • the present invention relates to a cable, and in particular to a profiled cable for use in a motor vehicle and adapted to the interior contour of the motor vehicle and a method of making the same.
  • Existing cables for motor vehicles generally consist of a core and an insulating layer coated on the core.
  • the cables used in motor vehicles are usually round, and some of the improved cables are flat. Since the circular cable has a circular cross section, the force on each point on the same circumference is isotropic, so that it is difficult to deform when subjected to an external force, making the harness cable difficult to bend.
  • the Chinese invention patent CN 104112508A discloses a new type of electric vehicle internal cable which adopts a flat design. Due to the flat structure, the bending radius in the direction perpendicular to the width of the solid core is three times the thickness of the finished product, and the softness is better than that of the circular soft solid core wire of the same cross-sectional area.
  • the solid core is laminated with a number of flat square copper strips that are not bonded together with other materials to ensure softness.
  • only the use of the same flat cable will lead to a large increase in wiring consumables, which increases the cost of wiring.
  • a single flat cable is prone to generate a single force. When the car is hit, the stress cannot be released significantly, causing the cable to break, resulting in a safety accident.
  • the Chinese invention patent CN 2388691Y sets the cross section of the cable core wire into a hollow open square shape, a hollow open rectangle, etc., and with the same current load amount, the cross-sectional area is reduced and the weight is reduced, thereby saving the production cost of the cable.
  • a single cable-shaped structure cannot be matched to the internal contour of the motor vehicle.
  • the cable cannot be connected to different shapes of cables to accommodate the wiring of the actual cable on a complex body contour.
  • the Chinese invention patent application CN 104384219A discloses an aluminum alloy lamp holder mandrel extrusion molding method, which comprises the following steps: preparation of extruded billet; fitter; heating of billet; placing the heated billet in a composite extrusion mold In the die, then mold clamping, extrusion molding; take out parts, cool down, polish and trim.
  • the resulting product is only a single shape and cannot meet the needs of achieving the connection of products of different shapes.
  • the object of the present invention is to provide a profiled cable which can improve the safety performance of a motor vehicle and save the production cost of the vehicle, and can also meet the needs of people for lightweight use of the vehicle body and preparation thereof. method.
  • a profiled cable, the core of the profiled cable being formed by at least two core segments having different cross-sectional shapes.
  • the special shape of the present solution means that the guiding core in the cable is formed by at least two guiding core segments having different cross-sectional shapes.
  • the shaped cable guide core is connected end to end by at least two core segments having different cross-sectional shapes, it can avoid the single force often occurring in the ordinary cable when the vehicle body is subjected to a violent impact, and quickly disperse the cable. The stress is applied to better avoid the cable from being broken by force, which greatly improves the safety performance of the motor vehicle.
  • the lead-core segment has an effective conductive cross-sectional area with a tolerance in the range of ⁇ 20%.
  • the effective conductive cross-sectional area inside each core segment may have certain tolerances, but the inventors believe that to ensure the safety of electricity, the tolerance The range should be ⁇ 20%. This value is relative to the effective conductive cross-sectional area of each core segment and does not define between different core segments.
  • the inventor summed up from multiple trials and creative improvements: when the effective conductive area tolerance of the cable is set at ⁇ 1%, ⁇ 2%, ⁇ 3%, ⁇ 4%, ⁇ 5%, ⁇ 6% , ⁇ 7%, ⁇ 8%, ⁇ 9%, ⁇ 10%, ⁇ 11%, ⁇ 12%, ⁇ 13%, ⁇ 14%, ⁇ 15%, ⁇ 16%, ⁇ 17%, ⁇ 18%, ⁇ At 19%, ⁇ 20%, the outer insulation of the cable portion exceeding the tolerance is not melted, and when the tolerance of the effective conductive area of the cable is set to more than ⁇ 20%, the outer insulation of some cables begins to melt, thereby The conductive safety of the entire profiled cable is compromised.
  • the inventors believe that the tolerance of the effective conductive cross-sectional area of the conductive cable is set to ⁇ 20%, and the setting of this tolerance range can effectively reduce the melting of the insulating layer caused by the excessive temperature of the partially conductive portion of the shaped cable. Through this scheme, the use of the shaped cable is safe.
  • core segment may be solid, or partially hollow, or may be completely hollow.
  • core segments can also be flexible.
  • the combination may be a solid core segment and a hollow core segment, or a solid core segment and a flexible core segment, or a solid core segment and a solid core segment, or The hollow core segment and the flexible core segment, or the hollow core segment and the hollow core segment, or the flexible core segment and the flexible core segment.
  • any combination of the above four different states of the core segments should be considered to be included in the present technology. In the case.
  • one end of one of the core segments abuts one end of the adjacent other core segment.
  • the upper surface of one end of the one of the core segments is in contact with the lower surface of one end of the adjacent other core segment.
  • connection manner may be soldered or crimped or welded or plugged.
  • the shape of the two ends is respectively connected to the core connecting members having the same cross-sectional shape of the two core segments.
  • the cross-sectional areas of the core connecting members are similar.
  • the cross-sectional areas of the lead connecting members are similar, and the uniformity of the conductive effect can be better achieved.
  • the core connecting members have equal cross-sectional areas. At this time, the conductive connection effect of the core connecting member is the best.
  • the profiled cable is connected according to the contour of the motor vehicle body.
  • the cable can be laid to meet the actual needs of the contours of various parts of the body, saving material and space, thereby saving the cost of the motor vehicle.
  • the profiled cable is superimposed and folded back.
  • the scheme of superimposing and folding back through the cable will eliminate the eddy current effect caused by the high-voltage current transmission, and will not affect the operation of other electrical appliances in the vehicle body, and thus can be better applied under the condition of high voltage and large current.
  • the core segment is an aluminum core or an aluminum alloy core.
  • the aluminum lead core (including the aluminum core or its alloy material) is used instead of the copper lead core which is conventionally used in the prior art, since the density of aluminum is only one third of that of copper, and the solid core resistance is based on electrical properties.
  • the difference in rate, under the premise of satisfying the same conductivity, the wire-to-diameter ratio of aluminum and copper is only 1.28 times, and the weight of aluminum is only half of the same current-carrying copper. Without increasing the space for cable loading, it can greatly Reducing the weight of the wire is conducive to the weight reduction of the car body.
  • the aluminum guide core (including the aluminum core or its alloy material) having a small specific gravity and a low material price can be used instead of the copper guide core having a high material price, which can reduce the material cost and the transportation cost, and save the production cost of the motor vehicle.
  • the aluminum core has an aluminum content of not less than 95%.
  • the aluminum alloy core is an aluminum copper alloy or an aluminum magnesium alloy or an aluminum lithium alloy or an aluminum manganese alloy or an aluminum zinc alloy or an aluminum silicon alloy.
  • Different alloys can be used to meet the functional requirements of the motor vehicle by different electrical, mechanical and weight requirements of the cable.
  • the core segment has an elliptical or polygonal cross section or an E or F or H or K or L or T or U or V or W or X or Y shape or Z-shaped or semi-arc or curved or wavy.
  • the polygon is a triangle or a quadrangle or a pentagon or a hexagon or an octagon.
  • cross-sectional shape of the core segment can be set to an elliptical shape, a polygonal shape, and other various non-circular shapes, which can better perform wiring according to the contour of the automobile body and reduce wiring consumables.
  • the combination of multiple cross-sections also allows for more options for body wiring and placement of body parts, thereby reducing vehicle production costs.
  • the inner angle of the cross section of the core segment is rounded.
  • the inner corners of the polygons are rounded to prevent the sharp corners of the core segments from piercing the insulation layer, and also prevent excessive current flow. As a result, the burr generates a discharge, causing breakdown, thereby protecting the insulating layer and prolonging the service life of the cable segment.
  • the outer core segment is coated with an insulating layer, and the insulating layer contour is in conformity with the core guiding segment.
  • the insulating layer covers the outer wall of the core segment, so the cross-sectional shape of each cable segment is determined by the shape of the core segment. In this way, the cable can be made in different shapes to suit the contours of the motor vehicle in accordance with the needs of different parts of the actual motor vehicle.
  • the insulating layer may be coated not only on the outer wall of the core segment but also on the junction of the core segments.
  • the manufacturing materials of the insulating layer include, but are not limited to, one or more of PVC, silicone rubber, TPE, XPE, PP, XLPE, FEP, ETFE, TPR and TPFE.
  • the core segment is connected to one or more of a solid cable or a partially solid cable or a hollow cable or a flexible cable.
  • a method of preparing the above-described shaped cable comprising the steps of:
  • the preparation method comprises the following steps:
  • the metal raw material is extruded by an extruder through an extruder, and the extruded semi-finished core guiding section is cooled to finally obtain a core guiding section;
  • Ii placing the core segment into an insulating layer extruder, extruding the insulating layer on the core segment, and bonding the core segment to the insulating layer;
  • Iii The lead segments with the insulating layer are joined.
  • the core segments are connected by welding or crimping or welding or plugging.
  • the special-shaped cable preparation method firstly obtains a core segment by an extrusion mechanism. After that, each segment of the core segment can be connected to obtain an insulating layer, or First, each segment of the core segment is made of an insulating layer, and then each segment of the core segment with an insulating layer is connected. Both preparation sequences are feasible.
  • the cable segments of the prepared segment with or without the insulating layer need to be laid and connected according to the actual contour of the motor vehicle body, thereby reducing wiring consumables and saving space. , greatly reducing production costs.
  • the tools and materials to be prepared include raw material aluminum rods, extruders, and coils.
  • the mold is maintained at a temperature above 360 ° C during extrusion.
  • the temperature is maintained above 360 ° C during the use of the mold to ensure that the aluminum does not pass through the mold during the extrusion process, and does not cause cooling and solidification due to contact with the low temperature mold, thereby ensuring the aluminum extrusion step. Smooth progress.
  • the heating time is 20-60 minutes according to the size of the mold, which ensures that the aluminum rod used is sufficiently heated to an optimum processing state, and the internal temperature of the mold caused by the short heating time of the large mold is prevented from being insufficient.
  • the mold is preheated by a heating furnace before extrusion molding, which can reduce production preparation time and improve preparation efficiency.
  • the metal raw material rod can be straightened and cleaned, so that the extrusion can be smoother and the quality of the obtained product can be improved.
  • the metal raw material rod is straightened by a straightening wheel, and the impurities and the oxide layer on the surface of the metal raw material rod are removed by a bar stock cleaning machine.
  • the semi-finished core guide segment is extruded at one time, and does not require annealing, heating, pickling, trimming and other auxiliary equipment to achieve short-flow and pollution-free production.
  • the extrusion method is continuous extrusion.
  • the extruder used is preferably a continuous extruder.
  • the metal raw material rod is placed in the continuous extruder; the continuous extruder is activated, and the extrusion wheel in the continuous extruder is used. Rotating friction generates heat and pressure.
  • the aluminum rod is melted and extruded from the mold to form a semi-finished core segment of the same shape as the mold.
  • the raw material metal raw material rod is continuously introduced into the rotating grooved pressing wheel, the metal raw material rod is subjected to radial pressing and friction in the fixing groove, and the metal raw material rod generates sufficient temperature under the pressing and frictional force. And reaching the recrystallization state, extruding from the mold through the cavity and molding once. During the entire extrusion process, the compactness of the material increases, and the crystal grains are uniform and dense, thereby lowering the electrical resistivity and improving the electrical conductivity.
  • the continuous metal raw material rod material can be used as a raw material to produce an ultra-long core lead segment.
  • the traditional processing method generally does not exceed 30-50 meters, and the length of the continuous extrusion method generally ranges from several kilometers to tens of thousands of meters, thereby improving production efficiency and reducing production cost.
  • the metal raw material rod in the continuous extrusion process generates sufficient heat through the thermal deformation process of deformation and friction, so that no external annealing, heating, etc. are required, and the unit energy consumption of the product is reduced.
  • the present invention also provides another method of preparing the above-mentioned shaped cable, the preparation method comprising the following steps:
  • the special-shaped cable can also be manufactured by a 3D printing technology. Specifically, after inputting the data of the shaped cable required by the automobile into the 3D printer, the 3D printer according to the shape, hardness, etc. of the shaped cable. The data prints out the shaped cable that the motor vehicle needs.
  • the core segment is prepared by a computer of a 3D printer, and the structure of the core segment is decomposed into several layers, and the constituent materials of the core segment are sent to the working area through the print head of the 3D printer to melt the constituent materials.
  • the movement of the table obtains a stacked cladding entity, ie a shaped core segment.
  • the 3D printer technology can adopt a laser beam method, an arc beam method or an electron beam method.
  • the preparation method comprises the following steps:
  • the product cast by the mold is molded once, and no secondary processing is required, and the shape is uniform, and the consistency is remarkably improved.
  • the insulating layer is formed by printing or coating or extrusion coating an insulating layer on the surface of the core.
  • the method for preparing the insulating layer is a melt-extrusion printing method in a 3D printer, and the material is heated and melted in the shower head.
  • the spray head moves along the cross-sectional profile of the part and the filling trajectory, while extruding or ejecting the molten material, the material solidifies rapidly and bonds with the surrounding material to form the insulating layer.
  • the method for preparing the insulating layer may also be applied to the surface of the guiding core by coating.
  • the material is sprayed onto the surface of the lead core under pressure in a coater or coating gun.
  • the applicator or applicator gun moves along the outer contour of the conductor, and after it is ejected, the material cures rapidly and bonds to the lead core to form the insulating layer.
  • the method for preparing the insulating layer may also be attached to the surface of the lead core by extrusion.
  • the material is heated to a molten state by a screw of an extruder, and extruded from a mold and bonded to the surface of the core segment under the action of the pressure of the extruder to form the insulating layer.
  • the cable of the present invention is formed by joining at least two cables having different cross-sectional shapes.
  • the tolerance of the effective conductive cross-sectional area of each lead core of the cable of the invention is within ⁇ 20%. This design can ensure the conductive performance of the shaped cable and avoid local overheating of the cable due to excessive difference in electrical conductivity of the cable, thereby avoiding A safety problem arises from local overheating.
  • the cable of the present invention is made of one or more of PVC, silicone rubber, TPE, XPE, PP, XLPE, FEP, ETFE, TPR and TPFE, which is coated on the outer wall of the lead core to make the cable segment
  • the cross-sectional shape is consistent with the core segment.
  • the cable of the present invention utilizes a shape of both ends and a cross section of the two leading conductor segments respectively required to be connected
  • the same core connecting component can solve the problem that the two cable segments cannot be directly connected due to different cross-sectional shapes, and can improve the connection efficiency and reduce the connection cost.
  • the cable of the present invention is superimposed and folded back by the cable, which eliminates the eddy current effect caused by the high voltage current transmission, thereby meeting the requirements of the electromagnetic compatibility of the whole vehicle, and does not affect the operation of other electrical appliances in the vehicle body, and thus can be in a high voltage and high current situation. Such as the new energy vehicle, etc., it is better applied.
  • the cable of the present invention replaces the existing copper core with an aluminum guide core (including an aluminum core or an alloy material thereof), and on the one hand, the weight of the aluminum guide core is light, and the weight of the vehicle body can be achieved;
  • the low price of the aluminum guide core can greatly reduce the production cost and transportation cost of the cable, thereby reducing the production cost of the motor vehicle.
  • the cable of the present invention when its core segment is elliptical or polygonal or E-shaped or F-shaped or H-shaped or K-shaped or L-shaped or T-shaped or U-shaped or V-shaped or W-shaped or X-shaped or Y-shaped Shape or Z-shaped or semi-arc or curved or wavy structure can better match the body contour and simplify the wiring process.
  • the inner corners of the polygonal core segments are treated by rounding, which avoids the sharp edges from piercing the flexible insulation layer and prevents the burrs from breaking through the insulation layer, effectively protecting the cable segments and prolonging their service life. Cable applications can also be improved.
  • the method for preparing a cable provided by the present invention is capable of preparing a core segment of different shapes according to the contour of a motor vehicle body, and then connecting the obtained guide core of the entire segment, and then coating the outer periphery of the obtained guide core with flexible insulation.
  • the cable is made in layers to reduce wiring consumables, save space, and greatly reduce cable production costs.
  • the method for preparing a cable provided by the present invention adopts a continuous extrusion process in an extrusion molding process to ensure that the product extruded at a high temperature has an optimum molding precision and a good cross-sectional shape, and the entire extrusion process.
  • the density of the material is increased, and the crystal grains are uniform and dense, thereby lowering the electrical resistivity, improving the electrical conductivity, and reducing the unit energy consumption of the product.
  • the method for preparing a cable adopts a 3D printing method to produce a core guiding segment and coating an insulating layer, has a wide processing range, high utilization rate of raw materials, and does not need to input more molds and equipment.
  • the product is trial-produced or small-volume production of a variety of shaped cables, the corresponding products can be quickly and quickly produced, thereby saving costs, improving efficiency, and meeting the increasingly diverse needs of the automotive field.
  • the method for preparing a cable provided by the present invention adopts a casting method to obtain a core guiding section, which is formed in one time, does not need to be further processed, and has a uniform shape, and the consistency of the product is remarkably improved.
  • FIG. 1 is a schematic structural view of a first preferred embodiment of a profiled cable of the present invention
  • Figure 2 is a bottom plan view showing the structure of the embodiment of Figure 1;
  • FIG. 3 is a schematic structural view of a second preferred embodiment of the profiled cable of the present invention.
  • FIG. 4 is a schematic structural view of a third preferred embodiment of the profiled cable of the present invention.
  • FIG. 5 is a schematic structural view of a fourth preferred embodiment of the profiled cable of the present invention.
  • FIG. 6 is a schematic structural view of a sixth preferred embodiment of the profiled cable of the present invention.
  • FIG. 7 is a schematic structural view of a seventh preferred embodiment of the profiled cable of the present invention.
  • Figure 8 is a process flow diagram of one of the preferred preparation steps of the profiled cable of the present invention.
  • a profiled cable, the core of the profiled cable being formed by at least two core segments having different cross-sectional shapes.
  • the guiding core of the cable 1 of the present embodiment is a core segment having three different shapes (the first guiding core segment 11 and the second respectively)
  • the core segment 12 and the third core segment 13) are connected end to end.
  • the cross section of the first core segment is W-shaped
  • the cross section of the second core segment is wavy
  • the cross section of the third core segment is curved.
  • An upper surface of a rear end of the first core lead segment is in contact with a lower surface of a front end of the second lead core segment, and a rear end of the second lead core segment is in contact with a front end of the third lead core segment .
  • An insulating layer made of PVC is coated on the outside of each lead core segment.
  • the cross-sectional shapes of the core segments are W-shaped, wavy, and curved, respectively.
  • the cross-sectional shape of the core segment may also be elliptical or polygonal or E-shaped. Or F or H or K or L or T or U or V or X or Y or Z or semi arc or the like.
  • the specific cross-sectional shape is set according to actual needs.
  • the effective conductive cross-sectional area inside each of the core segments In the present embodiment, in the actual production process, due to manufacturing errors or in order to adapt to different vehicle bodies, there may be certain tolerances in the effective conductive cross-sectional area inside each of the core segments, but the inventors believe that in order to ensure the safety of electricity, The tolerance should be within ⁇ 20%. It can ensure the conductive performance of the shaped cable and avoid the local overheating of the cable due to the excessive difference of the electrical conductivity of the cable, thus avoiding the safety problem caused by local overheating.
  • the effective cross-sectional area of the core segment of the cable In a typical automobile and its components, the effective cross-sectional area of the core segment of the cable is generally between 0.1 mm 2 and 180 mm 2 to meet the needs of different application scenarios.
  • the guide core segment of the present invention when the cross-sectional area thereof is 0.12 mm 2 , due to the tolerance range of the effective conductive cross-sectional area of the lead core segment At ⁇ 20%, so the effective conductive cross-sectional area of the core segment may be between 0.096 mm 2 and 0.144 mm 2 ; and, for example, in the embodiment of the present invention, when the core segment is applied to a starter cable, take sectional area 49mm 2, since the tolerance between the effective conducting cross-sectional area of the core guide section ⁇ 20%, the effective conducting cross-sectional area of the program guide core segments may 39.2mm 2 ⁇ 58.8mm 2 And, for example, in the embodiment in which the guide core segment of the present invention is applied to a power cord of an automobile, when the cross-sectional area thereof is 59 mm 2 , since the tolerance range of the effective conductive cross-sectional area of the lead core segment is ⁇ 20%, Therefore
  • the first core segment, the second core segment and the third core segment are both solid core segments.
  • the core segments may be partially hollow and completely hollow according to actual conditions. This allows for better alignment with the actual contours of the motor vehicle.
  • the core segments can be flexible. This can reduce the cable damage easily caused by the impact of the motor vehicle and improve the safety performance of the motor vehicle.
  • the cable is laid according to the characteristics of the curved shape of the vehicle bottom (the bottom surface of the vehicle is W-shaped, wavy, and curved from left to right) to realize the cable for the vehicle body. Fitted wiring, further conforming to the body, reducing wiring consumables, and helping to reduce assembly space.
  • the insulating layer of the cable is made of PVC. On the one hand, it guarantees its insulation performance, on the other hand, it also has waterproof performance and certain elasticity, wear resistance and hardness, ensuring that the flexible insulation layer will not be damaged during the processing of the cable.
  • the insulating layer of the cable may be made of one or more of silicone rubber, TPE, XPE, PP, XLPE, FEP, ETFE, TPR, and TPFE.
  • the inner angle of the cross section of the core segment is rounded. Since the cable segment adopts a polygonal structure and a non-circular structure, in order to protect the flexible insulating layer, the inner corners of the three-section core segments are rounded, that is, the inner corners of the guiding core of the cable are rounded, and on the one hand, sharpness can be avoided. The edge pierces the flexible insulating layer, and on the other hand, it can prevent the burr from being discharged due to excessive current flowing, causing breakdown, effectively protecting the cable and prolonging the service life of the cable.
  • the core segment is an aluminum core.
  • the guiding core is made of aluminum, which can reduce the weight of the wire and is beneficial to realize the weight reduction of the vehicle body.
  • the core segment may also be an aluminum alloy core, which may be an aluminum-copper alloy or an aluminum-magnesium alloy or an aluminum-lithium alloy or an aluminum-manganese alloy or an aluminum-zinc alloy or an aluminum-silicon alloy.
  • the three-segment-shaped polygonal core segments of the cable 1 in the embodiment are specifically: the first core segment 11 has a triangular cross section, and the second The core segment 12 has a quadrangular cross section, and the third core segment 13 has a pentagonal cross section.
  • the lower end of the rear end of the first core lead segment abuts the upper end of the front end of the second lead core segment, and the lower end of the front end of the first lead core segment abuts the upper end of the rear end of the third lead core segment.
  • the other implementations are the same as those in the first embodiment, and the present embodiment is not repeated.
  • the cross-sectional shape of the core guiding section is set to have different polygonal shapes such as a triangle, a quadrangle and a pentagon according to actual needs of the vehicle body.
  • the cross section of the core segment may also be set to other polygonal shapes according to actual needs, such as a hexagon, an octagon, or the like.
  • FIG. 4 a third embodiment of the present technical solution is shown.
  • the difference between this embodiment and the first embodiment is that the core of the cable 1 is not abutted by three different segments of the core segments.
  • the three-section core segments are connected by the core connecting member 2, that is, when the cross-sectional shapes of the adjacent two lead core segments are different, respectively, through one end shape and the two core segments respectively
  • the lead connecting members having the same cross-sectional shape are connected. Specifically, a rear end of the first core lead segment 11 and a front end of the second core lead segment 12 are connected by the lead core connecting member, and a rear end of the second lead core segment and the first portion
  • the front ends of the three core segments 13 are connected by the core connecting members.
  • the cross-sectional areas of the lead connecting members are approximate. Still further preferably, the cross-sectional areas of the connecting members are equal everywhere, at which time The conductive connection effect of the lead connecting member is the best.
  • the other embodiments are the same as those in the first embodiment, and the embodiments are not described in detail.
  • the guiding core of the cable 1 is not connected by two or three sections of the same core shape of the same form or material, but is connected by three sections of different cores of different shapes or materials.
  • the first core segment 11 is a flexible elliptical stranded core segment
  • the second core segment 12 is a solid core segment having an octagonal cross-sectional area
  • the third core segment 13 has a quadrilateral cross-sectional area.
  • Flexible stranded core segments are flexible stranded core segments.
  • the welding method is ultrasonic welding.
  • the connection between the flexible stranded core segment and the solid core segment having the octagonal cross-sectional area may be reversed.
  • the solid core segment shape having an octagonal cross-sectional area can be obtained by bending after extrusion.
  • the solid core segment morphology is obtained by casting molten aluminum in a mold; or alternatively, the solid core segment morphology is obtained by direct printing from a 3D printer.
  • the fifth embodiment is a fifth embodiment of the technical solution.
  • the embodiment is an improvement based on the fourth embodiment, that is, a section of the shaped cable, and a flexible stranded cable at any part thereof. Docked.
  • the profiled cable is solid.
  • the shaped cable may also be hollow or otherwise.
  • the profiled cable is bent and formed.
  • the shape of the shaped cable can be set according to actual needs.
  • FIG. 6 is a sixth specific implementation manner of the technical solution, and the embodiment and the foregoing embodiment The difference is that, in the second core segment 12 of the cable 1 of the embodiment, respectively, a solid cable with a triangular cross section, a solid cable with a quadrangular cross section, a partial solid cable with a cross section of a pentagon, and a cross section.
  • a hexagonal flexible cable is connected with a flexible cable having an octagonal cross section.
  • the cable connected to the second core segment may be solid, partially solid, hollow, or flexible, and may have an elliptical cross-sectional shape or E-shaped or F-shaped or H-shaped or K-shaped or L-shaped or T-shaped or U-shaped or V-shaped or W-shaped or X-shaped or Y-shaped or Z-shaped or semi-arc or curved or wavy in the cable A combination of one or any of several types of cables.
  • the different shaped solid cables and flexible cables are connected to the second core segments, and in other embodiments, they may also be connected to the first core segments 11 or other core segments. .
  • the second core lead segment is a solid structure, and the shape thereof is obtained by bending and superimposing.
  • the wire bundle branching structure is large, the wiring space and the cable material can be significantly saved.
  • FIG. 7 is a seventh embodiment of the present technical solution.
  • the difference between this embodiment and the above embodiment is that the shape of the first core segment 11 of the cable 1 of the present embodiment is laid along the contour of the vehicle body, and the cable is The second core segment 12 is formed to extend along the contour of the body.
  • the shape of the core segment is obtained by bending and laminating, and the beneficial effect is that when the core segment transmits a high voltage current, the superimposing manner eliminates the eddy current effect caused by the high voltage current transmission, and does not affect the vehicle.
  • the operation of other electrical appliances in the body are the same as the above embodiments, and the embodiments are not described in detail.
  • FIG. 8 is a first preparation method of the above-mentioned profiled cable disclosed in the present invention.
  • the preparation method is as follows.
  • a lead core is prepared by a core segment having a triangular cross section. , a core segment having a quadrangular cross section, and a cable having a pentagonal cross section and a core segment connected to each other.
  • the metal material used is aluminum.
  • the method steps for preparing the profiled cable core segment include: forming a core segment, joining the core segments, and fabricating the insulating layer.
  • the aluminum rod is extruded by an extruder through an extruder, and the extruded semi-finished aluminum core segment is cooled to finally obtain an aluminum core segment.
  • the specific manufacturing steps include:
  • the materials and equipment needed to prepare the aluminum conductor core are required, including raw material aluminum rods, molds, continuous extruders and coils.
  • the mold to be prepared includes: a triangular cable mold, a quadrilateral cable mold and a pentagon cable mold, before the mold is used, the mold is assembled and inspected to confirm that the mold finish and the alignment are in compliance with the preparation requirements. Otherwise, the mold needs to be polished and trimmed.
  • the triangular cable mold is installed in the cavity and fixed to the continuous extruder
  • the third step is to correct the aluminum rod and clean the surface thereof;
  • an extrusion molding step is performed. Put the aluminum rod into a tray, put it into the groove of the squeeze wheel of the continuous extruder, start the continuous extruder, and use the friction and pressure of the extruder.
  • the heated molten aluminum rod is extruded from a triangular cable mold to form a semi-finished aluminum core segment of the same shape as the triangular cable mold.
  • the quadrilateral cable mold and the pentagon cable mold are respectively installed in the cavity of the continuous extruder, and the continuous extruder is started, so that the aluminum rod is heated and melted and then extruded through the die to form a quadrangle and five.
  • One of the semi-finished aluminum core segments of the edge shape are respectively installed in the cavity of the continuous extruder, and the continuous extruder is started, so that the aluminum rod is heated and melted and then extruded through the die to form a quadrangle and five.
  • the mold is preheated by a heating furnace before extrusion molding.
  • the aluminum extrusion step is ensured smoothly.
  • the mold is squeezed.
  • the temperature is maintained above 360 ° C during the press forming process.
  • the three semi-finished aluminum core segments obtained in the above steps are respectively placed on a cooling system for cooling, and the blow drying device is turned on to dry the surface.
  • the three aluminum core segments obtained in the above steps are connected according to the contour of the motor vehicle body.
  • the lower end of the rear end of the triangular cable segment abuts the upper end of the front end of the quadrangular cable segment, and the lower end of the rear end of the quadrangular cable segment abuts the upper end of the front end of the pentagon cable segment.
  • the semi-finished aluminum core lead segment obtained above is passed through a pay-off device, a straightener, into an insulating layer extruder, and the insulating layer is extruded on the semi-finished aluminum core lead segment to form a shaped cable of the finished product.
  • the insulating layer The material may be prepared by selecting one or more materials of PVC or silicone rubber, TPE, XPE, PP, XLPE, FEP, ETFE, TPR and TPFE according to actual conditions.
  • the core segments can be input to a 3D printer by 3D printing according to actual parameters of the manufactured cable.
  • the core segment can make a corresponding mold by using 3D data, heat the aluminum to melt, cast the aluminum liquid into the mold, and after cooling, form the shape of the shaped cable.
  • the invention discloses a second preparation method of the above-mentioned special-shaped cable, and the preparation method is different from the above-mentioned first preparation method in that, after completing step S1, the aluminum rod is extruded by an extruder through a die, and the semi-finished product is extruded. After the aluminum core segment is cooled to obtain the aluminum core segment, an insulating layer is first formed for each segment of the aluminum core segment, and then the aluminum core segment with the insulating layer is peeled and joined to form a finished shaped cable.
  • the manufacturing process for making the insulating layer and the bonding is similar to the first preparation method described above, and will not be described here.
  • the invention also discloses a third preparation method of the above-mentioned special-shaped cable.
  • the special-shaped cable required for preparing the second embodiment is also taken as an example, and the following steps are included:
  • the shaped cable that is, the preceding 3D model data of a cable having a cross-sectional shape including a triangle, a quadrangle and a pentagon, the 3D model data is input into the 3D printer, and the guiding core of the shaped cable is passed through the 3D printer.
  • the mold core 3D data is used to make a mold, the raw material aluminum or aluminum alloy is heated to melt, and the aluminum liquid is cast or low pressure cast into the mold, and after cooling, the core portion of the shaped cable is formed.
  • the insulating layer is formed by printing or coating or extrusion-bonding the insulating layer on the surface of the lead core.
  • each of the core segments can be printed by 3D printing technology, or cast by a mold, and the core segments can be welded, crimped, welded, or plugged together, and finally, connected.
  • the surface of the core segment is printed or coated or extruded onto the surface to form a finished shaped cable.

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Abstract

一种异形电缆（1）及其制备方法。该异形电缆的导芯由至少两个横截面形状相异的导芯段（11、12、13）首尾相接而成。导芯段外部包覆有绝缘层，绝缘层轮廓与导芯段相贴合。该电缆具有良好的折弯性能，还能更好地贴合车身，节省耗材，同时提高其安全性能。该电缆使用铝或铝合金导芯，可实现车体的轻量化，减少机动车的生产成本。该制备方法包括导芯段制作（S1）、导芯段相接（S2）和绝缘层制作（S3）步骤，能够根据不同的生产需求，有效提高生产效率与生产量，降低生产成本。

Description

一种异形电缆及其制备方法 技术领域
本发明涉及一种电缆，具体地，涉及一种用于机动车，并能适应机动车内部轮廓进行设置的异形电缆及其制备方法。
背景技术
现有用于机动车的电缆，一般由导芯和包覆于导芯的绝缘层所组成。目前，机动车所使用的电缆通常为圆形，也有一部分改进的电缆呈扁状。圆形电缆因横截面为圆形，因此在同一圆周上各个点受力是各向同性的，导致在受到外力作用时，难以发生形变，使线束电缆难以折弯。
为此，中国发明专利CN 104112508A公开了一种采用扁平状设计的新型电动汽车内部用电缆。由于采用扁平结构，在垂直于实心导芯宽度方向上的弯曲半径为成品厚度的3倍，柔软性比同截面积同截面圆形软实心导芯电线更好。实心导芯是由多条扁平方形铜带层叠起来，中间没有使用其它材料粘合，确保柔软性。但由于机动车内部轮廓形状不一，仅使用相同扁平状的电缆会导致布线耗材大大增加，增加了布线的成本。同时，单种扁状电缆极易产生单根受力，当汽车受到碰撞时，应力无法显著释放，造成线缆的断折，从而发生安全事故。
另外，中国发明专利CN 2388691Y将电缆芯线截面设置成空心开口方形、空心开口矩形等，在具有同样电流负载量的情况下，使得截面积减小，重量减轻，从而可节约电缆的生产成本。但单一的电缆形状结构无法与机动车内部轮廓相匹配，该电缆不能将不同形状的电缆相接，以适应实际电缆在复杂的车身轮廓上的布线的需要。
而中国发明专利申请CN 104384219A公开了一种铝合金灯座芯棒挤压成型方法，包括以下步骤：挤压胚料的制备；钳工；坯料的加热；将加热后的坯料置于复合挤压模的凹模中，然后合模，挤压成型；取出零件，降温，打磨修整。但是所得产品仅为单一形状，不能满足实现各段不同形状的产品相接的需要。
发明内容
为了克服现有技术的不足，本发明的目的在于提供一种既能提高机动车安全性能，又能节约机动车生产成本，还能满足人们对车体轻量化的使用需求的异形电缆及其制备方法。
为解决上述问题，本发明所采用的技术方案如下：
一种异形电缆，所述异形电缆的导芯由至少两个横截面形状相异的导芯段首尾相接而成。
需要说明的是，本方案的异形指的是电缆中的导芯至少由两个横截面形状相异的导芯段首尾相接而成。同时，由于所述异形电缆导芯由至少两个横截面形状相异的导芯段首尾相接，能够在车身受到猛烈撞击时，避免普通电缆经常出现的单根受力的情况，快速分散电缆所承受的应力，从而更好地避免电缆受力撞断，大大地提高了机动车辆的安全性能。
优选地，所述导芯段有效导电横截面积的公差范围在±20％。
需要说明的是，在实际生产过程中，由于制造误差或者为了适应不同车身，每个导芯段内部的有效导电横截面积可能存在一定公差，但发明人认为，为保证用电安全，其公差范围应在±20％。此数值是相对于每个导芯段的有效导电横截面积而言，而非限定不同导芯段之间。发明人从多次试验以及富有创造性的改进过程中总结出：当线缆的有效导电面积的公差设置在±1％，±2％，±3％，±4％，±5％，±6％，±7％，±8％，±9％，±10％，±11％，±12％，±13％，±14％，±15％，±16％，±17％，±18％，±19％，±20％时，超过公差的电缆部分的外部绝缘层均没有熔化，而当线缆的有效导电面积的公差设置超过±20％时，部分线缆的外部绝缘层开始熔化，从而使整个异形电缆的导电安全性能受到破坏。因而，发明人认为，将导电线缆的有效导电横截面积的公差设置在±20％，此公差范围的设置可以有效地减少异形电缆因部分导电部分温度过高而导致的绝缘层熔化。通过此方案，满足异形电缆的使用用电安全。
需要说明的是，所述导芯段可以是实心的，或者是部分空心的，也可以是全部空心的。
进一步地，所述导芯段还可以是柔性的。
在相邻连接的导芯段中，其组合可以是实心导芯段与空心导芯段，或者是实心导芯段和柔性导芯段，或者是实心导芯段与实心导芯段，或者是空心导芯段与柔性导芯段，或者空心导芯段与空心导芯段，或者柔性导芯段和柔性导芯段。当然，上述四种不同状态的导芯段的任意组合均应被认为包括在本技术方 案中。
优选地，所述其中一个导芯段的一端与相邻的另一个导芯段的一端抵接。
优选地，所述其中一个导芯段的一端的上表面与相邻的另一个导芯段的一端的下表面相接。
需要说明的是，上述连接方式可以使用焊接或压接或熔接或插接的方式。
优选地，当所述相邻两个导芯段横截面形状相异时，通过一个两端形状分别与所述两个导芯段横截面形状相同的导芯连接部件相连接。
需要说明的是，利用一个两端形状分别与两个所需连接的导芯段横截面相同的导芯连接部件，可解决两个电缆段因横截面形状不同的原因无法直接相连接的问题。
更为优选地，所述导芯连接部件的各横截面面积相近。
需要说明的是，该导芯连接部件的各横截面面积相近，可更好地实现导电效果的一致性。作为其中一种优选的实施方式，所述导芯连接部件的横截面积处处相等。此时，所述导芯连接部件的导电效果一致性最佳。
优选地，所述异形电缆根据机动车车身轮廓相接。通过此方案，能够适应车身各部分轮廓的实际需要铺设电缆，节省材料及空间，进而节约机动车辆的成本。
优选地，所述异形电缆叠加回折延伸。
通过电缆叠加回折的方案，会消除由于高压电流传输引起的涡流效应，不影响车体内其他电器的运行，进而能够在高压大电流的情况下得到较好的应用。
优选地，所述导芯段是铝芯或铝合金芯。
需要说明的是，采用铝导芯(包括铝芯或其合金材料)代替现有技术惯常使用的铜导芯，由于铝的密度仅为铜的三分之一，而根据电气性能实心导芯电阻率的差异，在满足相同导电性能的前提下，铝与铜的线径比只相差1.28倍，铝材重量只有相同载流量铜材的一半，在不增加电缆装车空间的情况下，可大大减轻线材重量，有利于实现车体的轻量化。而且采用比重小，材质价格便宜的铝导芯(包括铝芯或其合金材料)代替比重大，材质价格高的铜导芯，可减少材料成本和运输成本，节约机动车辆的生产成本。
进一步优选地，所述铝芯的铝含量不少于95％。
优选地，所述铝合金芯是铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金。
通过对电缆的不同电气、机械性能以及重量要求，可以选用不同的合金来满足机动车的功能要求。
优选地，所述导芯段的横截面呈椭圆形或多边形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形结构。
优选地，所述多边形为三角形或四边形或五边形或六边形或八边形。
需要说明的是，导芯段的横截面形状可设置成椭圆形、多边形以及其他各类非圆形形状，能够更好地根据机动车车身的轮廓进行布线，减少布线耗材。多种截面的组合，也使车身布线和安置车身零件有更多的选择，从而降低车辆生产成本。
优选地，所述导芯段横截面的内角为倒圆角。
需要说明的是，若导芯段被制作成多边形时，将多边形各个内角设置为倒圆角，可防止导芯段锋利的边角刺破绝缘层，同时还可以防止因流经的电流过大从而毛刺产生放电，造成击穿，从而保护绝缘层，延长电缆段的使用寿命。
优选地，所述导芯段外部包覆有绝缘层，所述绝缘层轮廓与所述导芯段相贴合。
需要说明的是，所述绝缘层包覆导芯段的外壁，因此每一个电缆段的横截面形状是由导芯段的形状决定的。通过这种方式，电缆可根据实际机动车不同部位的需要，被制作成不同形状以适应机动车轮廓进行连接设置。
需要说明的是，所述绝缘层不仅可以包覆在导芯段的外壁，也可以包覆在各导芯段的相接处。
需要说明的是，绝缘层的制作材料包括但不限于PVC、硅橡胶、TPE、XPE、PP、XLPE、FEP、ETFE、TPR和TPFE的一种或多种。
优选地，所述导芯段与实心电缆或部分实心电缆或空心电缆或柔性电缆中一种或多种相接。
为实现上述第二个发明目的，本发明所采用的技术方案如下：
一种制备上述异形电缆的方法，所述制备方法包括以下步骤：
S1：将金属原材料利用模具通过挤压机挤压成型，挤出的半成品导芯段经过冷却，最终得到导芯段；
S2：将所述导芯段相接；
S3：将相接好的所述导芯段放入绝缘层挤出机中，将绝缘层挤出在导芯段 上，使所述导芯段与所述绝缘层贴合；
或者，所述制备方法包括以下步骤：
i：将金属原材料利用模具通过挤压机挤压成型，挤出的半成品导芯段经过冷却，最终得到导芯段；
ii：将所述导芯段放入绝缘层挤出机中，将绝缘层挤出在导芯段上，使所述导芯段与所述绝缘层贴合；
iii：将所述带有绝缘层的导芯段相接。
优选地，所述导芯段相接方式是焊接或压接或熔接或插接。
需要说明的是，从整体上来说，所述异形电缆制备方法均首先通过挤压机制得导芯段，在此之后，可先将各段导芯段相接后再制取绝缘层，也可以先将每段导芯段制取绝缘层后再将各段带有绝缘层的导芯段相接，这两种制备顺序均是可行的。
需要说明的是，在导芯段相接步骤中，将所制备的带有或不带有绝缘层的各段电缆段按机动车车身的实际轮廓需要铺设及相接，减少布线耗材，节约空间，大大降低生产成本。在本技术方案中，需要准备的工具和原料包括原材料铝杆、挤出机和线盘。
需要说明的是，若所述金属采用铝，则所述模具在挤压成型的过程中保持在360℃以上的温度。
需要说明的是，在模具的使用过程中保持在360℃以上的温度，保证铝在该温度下在挤压过程中经过模具时不会因接触低温模具而导致降温并凝固，确保铝挤压步骤的顺利进行。加热时间根据所述模具大小为20-60分钟，可确保所用铝棒充分加热至最佳加工状态，防止大模具加热时间过短导致的模具内部温度不足。
需要说明的是，所述模具在挤压成型前经加热炉进行预热，可减少生产准备时间，提高制备效率。
需要说明的是，在挤压步骤之前，可将金属原材料杆矫直和清刷，可使挤压更为顺利，提高所得产品质量。具体而言，将金属原材料杆经过矫直轮进行矫直，并用杆料在线清刷机对金属原材料杆表面的杂质和氧化层进行清除。
需要说明的是，半成品导芯段一次性挤压成型，不需要退火、加热、酸洗、切边等其他辅助设备，实现短流程无污染生产。
优选地，所述挤压方式是连续挤压。所采用的挤压机优选为连续挤压机。
需要说明的是，当采用连续挤压工艺时，将所述金属原材料杆放入所述连续挤出机内；启动所述连续挤出机，通过并利用连续挤出机内的挤压轮的旋转摩擦产生热量和压力将铝杆熔融后从所述模具中挤出，形成与所述模具相同形状的半成品导芯段。
其中，将原材料金属原材料杆连续引拽进入旋转有槽所述挤压轮中，金属原材料杆在固定槽中受到径向挤压和摩擦，在挤压和摩擦力下金属原材料杆产生足够的温度并达到再结晶状态，经由腔体从模具中挤出并一次成型。在整个挤压过程中，材料的密实度增加，晶粒均匀致密，从而使电阻率降低，提高了导电性能。
需要说明的是，采用连续的金属原材料杆盘料作为原材料，可生产超长度导芯段。传统加工方法一般不超过30-50米，利用连续挤压法长度一般可达数千米直到数万米之间，从而提高生产效率，降低生产成本。
需要说明的是，连续挤压过程金属原材料杆通过变形、摩擦的热变形过程产生足够热量，所以不需要外加退火、加热等，降低产品单位能耗。
需要说明的是，连续挤压生产过程中无压余、切边等工艺废料，材料利用率高，半成品导芯段成品率能达到95％以上。
本发明还提供另一种制备上述异形电缆的方法，所述制备方法包括以下步骤：
(1)将所述异形电缆的3D数据输入3D打印机中，所述3D打印机根据数据将所述异形电缆的导芯打印出来；
(2)绝缘层制作；
需要说明的是，所述异形电缆还可以通过3D打印技术所制得，具体来说，将机动车所需要的异形电缆的数据输入3D打印机后，3D打印机根据所述异形电缆的外形、硬度等数据将机动车需要的异形电缆打印出来。
其中，导芯段的制备方法是通过3D打印机的计算机，将导芯段的结构分解为若干层，通过3D打印机的打印头将导芯段的组成材料送至工作区域，使组成材料熔化，通过工作台的移动，获得堆积的熔覆实体，即成型的导芯段。
其中，3D打印机技术可以采用激光束方式或者电弧束方式或者电子束方式等方式。
又或者，所述制备方法包括以下步骤：
(1)根据所述异形电缆的3D数据制作模具，将金属原材料加热至熔化， 将金属液浇铸或低压铸造至模具中，冷却后形成所述异形电缆的导芯。
(2)绝缘层制作；
其中，模具浇注的产品，一次成型，不需要再进行二次加工，且形状统一，一致性得到显著提高。
优选地，所述绝缘层制作步骤是在所述导芯表面将绝缘层打印或涂覆或挤出贴合在其表面。
需要说明的是，绝缘层的制备方法，在3D打印机中采用熔融挤出成型的打印方式，材料在喷头内被加热熔化。喷头沿零件截面轮廓和填充轨迹运动，同时将熔化的材料挤出或喷出，材料迅速固化，并与周围的材料粘结，形成所述绝缘层。
需要说明的是，绝缘层的制备方法，也可以采用涂覆的方式贴合在所述导芯表面。材料在涂覆机或涂覆枪中在压力下喷涂在所述导芯的表面。涂覆机或涂覆枪沿着导体的外部轮廓移动，材料在被喷出后，迅速固化，并与所述导芯相粘接，形成所述绝缘层。
需要说明的是，绝缘层的制备方法，也可以采用挤出的方式贴合在所述导芯表面。材料通过挤出机的螺杆作用下，加热至熔融状态，并在挤出机压力的作用下，从模具中挤出并粘接在所述导芯段的表面上，形成所述绝缘层。
相比现有技术，本发明的有益效果在于：
1、本发明的电缆由至少两个横截面形状相异的电缆首尾相接而成。通过此方案，能够适应车身各部分轮廓的实际需要铺设电缆，节省耗材，从而降低车辆布线成本。同时，能够在车身受到猛烈撞击时，避免普通电缆经常出现的单根受力的情况，快速分散电缆所承受的应力，从而更好地避免电缆受力撞断，大大地提高了机动车辆的安全性能。
2、本发明的电缆各导芯段有效导电横截面积的公差范围在±20％，此设计能保证异形电缆的导电性能，避免由于电缆导电性能的过大差异产生线缆局部过热，从而避免产生因局部过热所产生的安全问题。
3、本发明的电缆采用PVC、硅橡胶、TPE、XPE、PP、XLPE、FEP、ETFE、TPR和TPFE的一种或多种制作绝缘层，其包覆于导芯的外壁，使得电缆段的横截面形状与导芯段相一致。通过此项技术，能够满足所述异形电缆在不同温度，不同湿度，不同化学环境下的使用要求。
4、本发明的电缆利用一个两端形状分别与两个所需连接的导芯段横截面相 同的导芯连接部件，可解决两个电缆段因横截面形状不同的原因无法直接相连接的问题，并且可以提升连接效率，降低连接成本。
5、本发明的电缆中通过电缆叠加回折，会消除由于高压电流传输引起的涡流效应，从而满足整车电磁兼容性的需求，不影响车体内其他电器的运行，进而能够在高压大电流情况，如新能源汽车等情况下得到较好的应用。
6、本发明的电缆采用铝导芯(包括铝芯或其合金材料)替代现有的铜芯，一方面由于铝导芯质量较轻，可实现车体的轻量化；另一方面，还由于铝导芯价格较低，能够大大降低电缆的生产成本和运输成本，从而减少机动车的生产成本。
7、本发明的电缆，当其导芯段形状为椭圆形或多边形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形结构时，能够更好匹配车身轮廓，简化布线工艺。同时，多边形导芯段的各个内角用倒圆角的方式进行处理，可以避免锋利边线刺破柔性绝缘层，以及防止毛刺造成击穿绝缘层，有效地保护了电缆段，延长其使用寿命，多边形电缆的应用也能够提升。
8、本发明所提供的制备电缆的方法，能够根据机动车车身的轮廓分段制备不同形状的导芯段，然后相接所得整段所需导芯，再在所得导芯外部包覆柔性绝缘层制得电缆，可减少布线耗材，节约空间，大大降低线缆生产成本。
9、本发明所提供的制备电缆的方法，在挤压成型过程中采用连续挤压的工艺，确保了在高温下挤出的产品有最佳的成型精度和良好的截面形状，整个挤压过程中材料的密实度增加，晶粒均匀致密，从而使电阻率降低，提高了导电性能，同时还能降低产品单位能耗。
10、本发明所提供的制备电缆的方法，采用3D打印的方法制作导芯段及涂覆绝缘层时，加工范围广，原材料利用率高，不需要投入较多的模具和设备。当产品试制或小批量生产多品种的异形电缆时，能够快捷迅速的制成相应的产品，从而节约成本，提升效率，满足汽车领域日益多样化的需求。
11、本发明所提供的制备电缆的方法，采用浇注的方法获得导芯段，一次成型，不需要再进行二次加工，且形状统一，产品的一致性得到了显著的提高。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图，详细说明如 下。
附图说明
图1为本发明异形电缆的第一种优选实施方式的结构示意图；
图2为图1实施方式的结构示意图的仰视图；
图3为本发明异形电缆的第二种优选实施方式的结构示意图；
图4为本发明异形电缆的第三种优选实施方式的结构示意图；
图5为本发明异形电缆的第四种优选实施方式的结构示意图；
图6为本发明异形电缆的第六种优选实施方式的结构示意图；
图7为本发明异形电缆的第七种优选实施方式的结构示意图；
图8为本发明异形电缆其中一种优选的制备方法步骤的工艺流程图；
图中，1、电缆；11、第一导芯段；12、第二导芯段；13、第三导芯段；2、连接部件。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效，以下结合附图及较佳实施例，对依据本发明的具体实施方式、结构、特征及其功效，详细说明如下：
一种异形电缆，所述异形电缆的导芯由至少两个横截面形状相异的导芯段首尾相接而成。
实施例一
如图1和2所示是本技术方案的第一种具体实施方式，本实施例的电缆1的导芯是由三段形状不同的导芯段(分别为第一导芯段11、第二导芯段12和第三导芯段13)首尾相接而成的。
在本实施例中，第一导芯段的横截面呈W形、第二导芯段的横截面呈波浪形，第三导芯段的横截面呈弧形。所述第一导芯段的后端的上表面与所述第二导芯段的前端的下表面相接，所述第二导芯段的后端与所述第三导芯段的前端相抵接。在各导芯段外部包覆有PVC材质的绝缘层。
在本实施例中，所述导芯段的横截面形状分别呈W形、波浪形和弧形。在其他的实施方式中，所述导芯段的横截面形状还可以呈椭圆形或多边形或E形 或F形或H形或K形或L形或T形或U形或V形或X形或Y形或Z形或半弧形等。具体横截面形状根据实际需要而设置。
在本实施例中，在实际生产过程中，由于制造误差或者为了适应不同车身，每个导芯段内部的有效导电横截面积可能存在一定公差，但发明人认为，为保证用电安全，其公差范围应在±20％。能保证异形电缆的导电性能，避免由于电缆导电性能的过大差异产生线缆局部过热，从而避免产生因局部过热所产生的安全问题。在通常的汽车及其部件中，所述电缆的导芯段有效横截面积一般在0.1mm2～180mm2之间，以适应不同应用场景需要。具体而言，例如，在本方案导芯段应用在汽车的门线缆中的实施方式中，当其横截面积取0.12mm2时，由于所述导芯段有效导电横截面积的公差范围在±20％，因此所述导芯段有效导电横截面积取值可在0.096mm2～0.144mm2之间；又例如，在本方案导芯段应用在起动机电缆的实施方式中，当其横截面积取49mm2时，由于所述导芯段有效导电横截面积的公差范围在±20％，本方案导芯段的有效导电横截面积可在39.2mm2～58.8mm2之间；又例如，在本方案导芯段应用在汽车的电源线的实施方式中，当其横截面积取59mm2时，由于所述导芯段有效导电横截面积的公差范围在±20％，因此所述导芯段有效导电横截面积取值可在47.2mm2～70.8mm2之间；又例如，在本方案导芯段应用在新能源汽车电源电缆的实施方案中，当其横截面积取180mm2时，由于所述导芯段有效导电横截面积的公差范围在±20％，因此所述导芯段有效导电横截面积取值可在144mm2～216mm2之间。
在本实施例中，第一导芯段、第二导芯段和第三导芯段均是实心导芯段结构。在其他的实施方式中，导芯段可以是根据实际情况设置成部分空心、全部空心的。这样能更好地配合机动车的实际轮廓需要进行铺设。另外，所述导芯段可以是柔性的。这样可降低机动车因撞击而容易造成的电缆损坏，提高机动车的安全性能。
在本实施例中，电缆根据机动车车底呈变换曲形(该段车底表面从左到右依次呈W形、波浪形和弧形)的特点进行铺设，以实现电缆对于该段车身的贴合布线，进一步贴合车身，减少布线的耗材，有利于减少装配空间。
在本实施例中，电缆的绝缘层材质是PVC。一方面保证其绝缘性能，另一方面还具有防水性能以及一定的弹性、耐磨性和硬度，保证电缆在加工成型过程中，柔性绝缘层不会受到损害。在其他实施方式中，所述电缆的绝缘层的材质还可以是硅橡胶、TPE、XPE、PP、XLPE、FEP、ETFE、TPR和TPFE的一种或多种。
在本实施例中，所述导芯段横截面的内角为倒圆角。由于电缆段采用了多边形结构非圆形结构，为保护柔性绝缘层，将三段导芯段的各个内角作圆角处理，即电缆的导芯的各个内角为倒圆角，一方面可以避免锋利边线刺破柔性绝缘层，另一方面还可以防止因流经的电流过大从而毛刺产生放电，造成击穿，有效地保护了电缆，延长了电缆的使用寿命。
在本实施例中，所述导芯段是铝芯。所述导芯的制作材料为铝，能减轻线材重量，有利于实现车体的轻量化。在其他实施方式中，导芯段还可以是铝合金芯，所述铝合金芯可以是铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金等。
实施例二
如图3所示是本技术方案的第二种具体实施方式。本实施例与实施例一的区别在于，本实施例中的电缆1的所述三段形状不同的多边形导芯段，具体而言是：第一导芯段11的横截面呈三角形，第二导芯段12的横截面呈四边形，第三导芯段13的横截面呈五边形。第一导芯段的后端的下端与第二导芯段的前端的上端相抵接，第一导芯段的前端的下端与第三导芯段的后端的上端相抵接。而其他实施情况与实施例一相同，本实施例不再累述。
在本实施例中，所述导芯段横截面形状根据车身的实际需要所设置呈三角形、四边形和五边形等不同多边形形状。在其他的实施方式中，所述导芯段横截面也可以根据实际需要设置成其他多边形形状，例如六边形、八边形等。
实施例三
如图4所示是本技术方案的第三种具体实施方式。本实施例与实施例一的区别在于，所述电缆1的导芯并不是由三段形状不同的导芯段通过抵接而成的。三段导芯段之间是通过导芯连接部件2而连接的，即当所述相邻两个导芯段横截面形状相异时，通过一个两端形状分别与所述两个导芯段横截面形状相同的导芯连接部件相连接。具体来说，所述第一导芯段11的后端与所述第二导芯段12的前端通过所述导芯连接部件相连接，所述第二导芯段的后端与所述第三导芯段13的前端通过所述导芯连接部件相连接。
为保证导电效果的一致性，在本实施例中，该导芯连接部件的各横截面面积近似。作为更进一步地优选，所述连接部件的横截面积处处相等，此时所述 导芯连接部件的导电效果一致性最佳。而其他实施方式与实施例一相同，本实施例不再累述。
实施例四
如图5所示是本技术方案的第四种具体实施方式。本实施例中所述电缆1的导芯并不是由两段或三段相同形态或材质的导芯段相连接，而是由三段不同形态或材质的导芯段相连。具体而言，第一导芯段11是柔性椭圆形绞合导芯段，第二导芯段12是截面积为八边形的实心导芯段，第三导芯段13是截面积为四边形的柔性绞合导芯段。所述第一导芯段的后端的下端与所述第二导芯段的前端的上端通过焊接方式相连接，所述第二导芯段的后端的上端与第三导芯段的前端的下端通过焊接方式相连接。作为其中一种优选实施方式，焊接方式为超声波焊接。柔性绞合导芯段与所述截面积为八边形的实心导芯段之间的连接，上下端面可颠倒。
作为其中一种实施方式，所述截面积为八边形的实心导芯段形态可以通过挤出后弯折得到。在其他的实施方式中，所述实心导芯段形态结构通过熔融的铝液在模具中浇铸而获得的；又或者，所述实心导芯段形态结构通过3D打印机直接打印获得。
而其他实施方式与实施例一相同，本实施例不再累述。
实施例五
实施例五是本技术方案的第五种具体实施方式，本实施例是在上述实施例四基础上的一种改进，即是由一段成型的异形电缆，在其任意部位与柔性绞合线缆相接。
在本实施例中，所述异形电缆是实心的。当然，如上述实施例所述，所述异形电缆还可以是空心或其他形态。
在本实施例中，所述异形电缆是弯折成型的。当然，如上述实施例所述，所述异形电缆的形状可根据实际需要而设置。
具体异形电缆的实施方式与前述实施例相同，本实施例不再累述。
实施例六
如图6所示是本技术方案的第六种具体实施方式，本实施例与上述实施例 的区别在于：在本实施例电缆1的第二导芯段12上，分别与横截面为三角形的实心电缆，横截面为四边形的实心电缆，横截面为五边形的部分实心电缆，横截面为六边形的柔性电缆，横截面为八边形的柔性线缆相连接。在其他的实施方式中，与第二导芯段相连接的电缆还可以是实心的，或是部分实心的，又或是空心的，还可以是柔性的，其横截面形状可以为椭圆形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形结构的电缆中的一种或任意几种电缆的组合。
在本实施例中，所述不同形状的实心电缆、柔性线缆与第二导芯段相连接，在其他的实施方式中，其还可以与第一导芯段11或其他导芯段相连接。
在本实施例中，所述第二导芯段是实心结构，其形态通过折弯叠加得到，当线束分支结构较多时，可显著节省布线空间与线缆材料。
而其他实施方式与上述实施例相同，本实施例不再累述。
实施例七
如图7所示是本技术方案的第七种具体实施方式，本实施例与上述实施例的区别在于：本实施例电缆1的第一导芯段11的形态沿车身轮廓铺设，而电缆的第二导芯段12形态沿车身轮廓叠加回折延伸。
在本实施例中，所述导芯段形态通过折弯叠压得到，其有益效果是当导芯段传输高压电流时，相互叠加的方式会消除由于高压电流传输引起的涡流效应，不影响车体内其他电器的运行。而其他实施方式上述实施例相同，本实施例不再累述。
异形电缆制备方法一
如图8所示是本发明公开的上述异形电缆的第一种制备方法，本制备方法以制备上述实施例二的电缆为例，即需制备一条导芯由一个横截面呈三角形的导芯段、一个横截面呈四边形的导芯段，以及一个横截面呈五边形的导芯段相接而成的电缆。所用金属材料为铝。本制备异形电缆导芯段的方法步骤包括：导芯段制作、导芯段相接以及绝缘层制作。
S1：导芯段制作：
将铝棒利用模具通过挤压机挤压成型，挤出的半成品铝导芯段经过冷却，最终得到铝导芯段，具体制作步骤包括：
第一步，需要准备制备铝导芯所需材料和设备，包括原材料铝杆、模具、连续挤出机和线盘。其中，需要准备的模具包括：一个三角形电缆模具、一个四边形电缆模具和一个五边形电缆模具，在使用模具之前，先对模具进行装配检查，确认模具的光洁度和对中度符合制备的要求，否则需要对模具进行抛光、修整处理。
第二步，将三角形电缆模具安装在腔体中，并安装固定到连续挤压机中；
第三步，对铝杆进行矫正和对其表面进行清洁；
第四步，在上述步骤完成后，进行挤压成型步骤。将成盘的铝杆经过放线架、矫直器和清刷机，放入到连续挤压机的挤压轮凹槽中，启动连续挤压机，利用所述挤出机的摩擦和压力，将加热熔融的铝杆从三角形电缆模具中挤出，形成一条与三角形电缆模具相同形状的半成品铝导芯段。
之后，按上述步骤分别将四边形电缆模具、五边形电缆模具安装在连续挤压机的腔体中，并启动连续挤压机，使铝杆加热熔融后通过模具挤出，形成呈四边形和五边形形状的半成品铝导芯段各一条。
为减少生产准备时间，提高制备效率，作为其中一种优选的实施方式，所述模具在挤压成型前经加热炉进行预热。
为保证铝在该温度下在挤压过程中经过模具时不会因接触低温模具而导致降温并凝固，确保铝挤压步骤的顺利进行，作为其中一种优选的实施方式，所述模具在挤压成型的过程中保持在360℃以上的温度。
第四步，将上述步骤所得的三条半成品铝导芯段分别放在冷却系统上进行冷却，并开启吹干装置将表面吹干。
S2：导芯段相接：
将上述步骤所得铝导芯段相接，具体步骤如下：
将上述步骤中所得的三条铝导芯段按机动车车身轮廓相接。其中，三角形电缆段的后端的下端与四边形电缆段的前端的上端相抵接，四边形电缆段的后端的下端与五边形电缆段的前端的上端相抵接。
相接时，具体采用的是焊接的方式。在其他的实施方式中，铝导芯段之间通过压接或熔接或插接等方式均是可行的。
S3：绝缘层制作：
将上述所得半成品铝导芯段，经过放线器，矫直器，进入到绝缘层挤出机中，将绝缘层挤出在半成品铝导芯段上，形成完成品的异形电缆。所述绝缘层 材料可根据实际情况选择PVC或硅橡胶、TPE、XPE、PP、XLPE、FEP、ETFE、TPR和TPFE的一种或多种材料进行制备。
作为其中一种优选的实施方式，所述导芯段可根据所制电缆的实际参数输入至3D打印机中通过3D打印所得。
作为其中一种优选的实施方式，所述导芯段可以利用3D数据制作相应模具，将铝加热至熔化，将铝液浇注至模具中，冷却后，使其形成所述异形电缆的形状。
异形电缆制备方法二
本发明公开了上述异形电缆的第二种制备方法，本制备方法与上述第一种制备方法的区别在于：在完成步骤S1，即将铝棒利用模具通过挤压机挤压成型，挤出的半成品铝导芯段经过冷却，得到铝导芯段后，首先对每一段铝导芯段制作绝缘层，再将带有绝缘层的铝导芯段去皮相接，形成成品异形电缆。制作绝缘层及相接的制作过程与上述第一种制备方法相似，在此不再累述。
异形电缆制备方法三
本发明还公开了上述异形电缆的第三种制备方法，，在本制备方法中，同样以制备实施例二所需异形电缆为例进行阐述，包括以下步骤：
(1)将所述异形电缆，即创建一段横截面形状包括三角形、四边形和五边形的电缆的先行3D模型数据，将3D模型数据输入到3D打印机中，通过3D打印机将异形电缆的导芯打出；
或者，采用导芯段3D数据制作模具，将原材料铝或铝合金加热至熔化，将铝液浇铸或低压铸造至模具中，冷却后形成所述异形电缆的导芯段。
(2)绝缘层制作，所述绝缘层制作步骤是在所述导芯表面将绝缘层打印或涂覆或挤出贴合在其表面。
(3)将所述带有绝缘层的导芯段连接端的绝缘皮去掉后，通过焊接，压接，熔接，或插接连在一起，形成成品异形电缆。
或者，也可以将每一段导芯段通过3D打印技术打印出来，或通过模具浇铸出来，再将所述的导芯段，通过焊接，压接，熔接，或插接连在一起，最后，在连接好的所述导芯段的表面，将绝缘层打印或涂覆或挤出贴合在其表面，形成成品异形电缆。

Claims (19)

  1. 一种异形电缆，其特征在于，所述异形电缆的导芯由至少两个横截面形状相异的导芯段首尾相接而成。
  2. 根据权利要求1所述的异形电缆，其特征在于，所述导芯段有效导电横截面积的公差范围在±20％。
  3. 根据权利要求1所述的异形电缆，其特征在于，所述其中一个导芯段的一端与相邻的另一个导芯段的一端抵接。
  4. 根据权利要求1所述的异形电缆，其特征在于，所述其中一个导芯段的一端的上表面与相邻的另一个导芯段的一端的下表面相接。
  5. 根据权利要求1所述的异形电缆，其特征在于，当所述相邻两个导芯段横截面形状相异时，通过一个两端形状分别与所述两个导芯段横截面形状相同的导芯连接部件相连接。
  6. 根据权利要求1所述异形电缆，其特征在于，所述异形电缆根据机动车车身轮廓相接。
  7. 根据权利要求1所述异形电缆，其特征在于，所述异形电缆叠加回折延伸。
  8. 根据权利要求1所述的异形电缆，其特征在于，所述导芯由铝合金或含量不小于95％的纯铝组成。
  9. 根据权利要求8所述的异形电缆，其特征在于，所述铝合金是铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金。
  10. 根据权利要求1所述的异形电缆，其特征在于，所述导芯段的横截面呈椭圆形或多边形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形结构。
  11. 根据权利要求10所述的异形电缆，其特征在于，所述多边形为三角形或四边形或五边形或六边形或八边形。
  12. 根据权利要求10所述的异形电缆，其特征在于，所述导芯段横截面的内角为倒圆角。
  13. 根据权利要求1所述的异形电缆，其特征在于，所述导芯段外部包覆有绝缘层，所述绝缘层轮廓与所述导芯段相贴合。
  14. 根据权利要求1所述的异形电缆，其特征在于，所述导芯段与实心电 缆或部分实心电缆或空心电缆或柔性电缆中的一种或多种相接。
  15. 一种制备根据权利要求1所述异形电缆的方法，其特征在于，所述制备方法包括以下步骤：
    S1：将金属原材料利用模具通过挤压机挤压成型，挤出的半成品导芯段经过冷却，最终得到导芯段；
    S2：将所述导芯段相接；
    S3：将相接好的所述导芯段放入绝缘层挤出机中，将绝缘层挤出在导芯段上，使所述导芯段与所述绝缘层贴合；
    或者，所述制备方法包括以下步骤：
    i：将金属原材料利用模具通过挤压机挤压成型，挤出的半成品导芯段经过冷却，最终得到导芯段；
    ii：将所述导芯段放入绝缘层挤出机中，将绝缘层挤出在导芯段上，使所述导芯段与所述绝缘层贴合；
    iii：将所述带有绝缘层的导芯段相接。
  16. 根据权利要求15所述的制备方法，其特征在于，所述导芯段相接方式是焊接或压接或熔接或插接。
  17. 根据权利要求15所述的制备方法，其特征在于，所述挤压成型的方式是连续挤压。
  18. 一种制备根据权利要求1所述异形电缆的方法，其特征在于，所述制备方法包括以下步骤：
    将所述异形电缆的3D数据输入3D打印机中，所述3D打印机根据数据将所述异形电缆的导芯打印出来；
    绝缘层制作；
    或者，所述制备方法包括以下步骤：
    根据所述异形电缆的3D数据制作模具，将金属原材料加热至熔化，将金属液浇铸或低压铸造至模具中，冷却后形成所述异形电缆的导芯；
    绝缘层制作；
  19. 根据权利要求18所述的制备方法，其特征在于，所述绝缘层制作步骤是在所述导芯表面将绝缘层打印或涂覆或挤出贴合在其表面。
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