WO2020119308A1 - 一种用于新能源汽车充电的空心电缆制造方法及电缆 - Google Patents

一种用于新能源汽车充电的空心电缆制造方法及电缆 Download PDF

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WO2020119308A1
WO2020119308A1 PCT/CN2019/114380 CN2019114380W WO2020119308A1 WO 2020119308 A1 WO2020119308 A1 WO 2020119308A1 CN 2019114380 W CN2019114380 W CN 2019114380W WO 2020119308 A1 WO2020119308 A1 WO 2020119308A1
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core
conductor
copper
layer
cable
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PCT/CN2019/114380
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English (en)
French (fr)
Inventor
张广柱
张东杰
王雪松
祝军
李斌
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江苏上上电缆集团有限公司
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    • 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
    • H01B13/02—Stranding-up
    • 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
    • H01B13/14—Insulating conductors or cables by extrusion
    • 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
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • 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
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/148—Selection of the insulating material therefor
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/221—Sheathing; Armouring; Screening; Applying other protective layers filling-up interstices
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • 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
    • H01B7/0045—Cable-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
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0216—Two layers
    • 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
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • 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
    • 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
    • H01B7/187—Sheaths comprising extruded non-metallic layers
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/2806—Protection against damage caused by corrosion
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
    • 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
    • H01B7/42—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
    • H01B7/421—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation
    • H01B7/423—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid
    • H01B7/425—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid the construction being bendable
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables

Definitions

  • the technical scheme belongs to the technical field of cables, and specifically relates to a hollow cable manufacturing method and cables.
  • lithium ion power batteries commonly used in new energy vehicles have the problems of low specific energy and short driving range on a single charge. Therefore, under the current situation that the power battery cannot provide more driving range, if the charging of the battery can be accelerated, the fatal weakness of the short driving range of the electric vehicle is solved from another angle.
  • the rapid charging has become a demand for development.
  • the three-way catalytic technology and graphene technology are gradually mature, and the specific energy of the power battery is constantly increasing. This requires fast charging in the future, while satisfying the high-power charging of the battery and the transfer of the high-power charging.
  • the conductor cross section of the traditional charging cable needs to reach 185mm 2 or 240mm 2 , the cable has a large weight, a large outer diameter, and is inconvenient to use. If the current rises to 500A again, the conductor cross-section and outer diameter of the charging cable need to continue to increase, which brings disadvantages such as heavy cable, not easy to bend, high procurement cost, inconvenient operation, and difficult to control production and processing.
  • the current of high-power charging is large (from 250A to 400A and above).
  • the diameter of the wire harness becomes thicker (50mm 2 or more), the operability of charging is reduced, and the economics of the scheme is reduced.
  • High-power charging technology includes cooling system technology, cooling cable technology and cooling interface technology, cable temperature rise test technology and other aspects.
  • this technical solution proposes a hollow cable and a manufacturing method thereof, specifically:
  • a hollow cable the structure of which is that the cable core is sequentially wrapped around the cladding and the outer sheath; the cable core is composed of a circulating cooling hose and a plurality of cables twisted, and the gap between each cable is filled Filled; each cable is:
  • Main power line core It is composed of the main power line core conductor which is sequentially wrapped with an inner insulation layer and an outer insulation layer, and a hollow cavity penetrating the entire cable is provided between the inner and outer insulation layers, and the hollow cavity constitutes a tubular channel;
  • hollow cavities which are symmetrical around the main power core; there are connecting ribs between adjacent hollow cavities; an anti-adhesive layer is provided between the inner insulating layer and the connecting rib; the anti-adhesive layer is the inner insulating layer Composition of anti-adhesion material applied on the outside;
  • Auxiliary power core It is composed of auxiliary power core copper conductor wrapped with auxiliary power core insulation layer;
  • Signal core group the signal core is composed of the copper conductor of the signal core group wrapped with an insulating layer, and a plurality of signal cores are twisted to form a signal core cable core, the signal core cable core is wrapped with a metal winding cladding, and the metal winding cladding is outside Wrapped with metal shielding layer; the gap between multiple signal cores is filled with filling;
  • Ground core is composed of the ground core conductor wrapped around the ground core insulation layer, and the ground core conductor is composed of multiple strands of copper wire;
  • the circulating cooling hose a hollow pipe extruded from a thermoplastic elastomer material.
  • the inner sheath of the cable core is also wrapped around the cladding layer, the inner sheath is wrapped with a mesh structure composed of metal wires, and the mesh structure has an isolation layer outside, and the isolation layer is wrapped with an outer sheath;
  • the filling rope material constituting the cable core is polypropylene filling rope
  • the wrapping layer outside the cable core is composed of a non-woven tape, the covering rate of the wrapping tape is not less than 5mm, the thickness of the non-woven tape is 0.1mm; the nominal thickness of the outer sheath is not less than 1.7mm.
  • the inner sheath is composed of thermoplastic elastomer sheath material extruded, the thickness of the inner sheath is not less than 0.5mm;
  • the mesh density of the mesh structure is not less than 80%.
  • the metal wire is tinned copper wire or bare copper wire. Among them, the resistivity of tinned copper wire at 20°C ⁇ 0.01780 ⁇ mm 2 /m, the resistivity of bare copper wire at 20°C ⁇ 0.017241 ⁇ mm 2 /m;
  • the elongation of the network structure is not less than 15%;
  • the isolation layer is made of environmentally friendly non-hygroscopic material, and the thickness of the isolation layer is not more than 0.1mm.
  • the outer surface of the outer insulation layer of the main power core is wrapped with a reinforced/explosion-proof layer;
  • the reinforced/explosion-proof layer is composed of a metal wire braid, a metal tape wrap or a fiber wire braid;
  • the main power wire core conductor is also wrapped with a non-woven fabric wrapping layer, the wrapping rate of the wrapping is not less than 5mm, and the thickness of the non-woven fabric tape is 0.1mm;
  • the inner insulation layer is wrapped around the cladding layer, the nominal thickness of the inner insulation layer is 0.7mm at the thinnest;
  • the outer insulation layer is composed of thermoplastic elastomer insulation material, the nominal thickness of the outer insulation layer is not less than 1.0mm.
  • the anti-blocking layer is composed of an anti-blocking material applied to the surface of the inner insulating layer (the anti-blocking material may be an inorganic or organic polymer anti-blocking material in the prior art).
  • main power core conductor and the ground core conductor are the same, and they are all composed of stranded bare copper monofilament strands;
  • the diameter of bare copper monofilament is 0.1mm ⁇ 0.2mm; the twisted pitch of bare copper monofilament is not greater than 18 times the outer diameter of the conductor after stranding, and the strand pitch of each bare copper filament is not greater than the stranded strand 35 times the outer diameter;
  • the bare copper monofilament is annealed bare copper monofilament.
  • the oxygen content of copper in the bare copper monofilament is not more than 0.001%, and the volume resistivity at 20°C is not more than 0.01701 ⁇ .mm 2 /m.
  • the requirements of the copper conductor of the auxiliary power line and the copper conductor of the signal core group are the same, they are all copper foil conductors; the copper foil conductor is formed by butting the copper foil on the fiber surface and then twisting with the copper monofilament;
  • the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20°C is not more than 0.01701 ⁇ .mm 2 /m.
  • the pitch diameter ratio of multiple signal wire cores and filled rope strands to constitute the signal core cable core is not greater than 20 times;
  • the metal wrap layer is composed of overlapping aluminum foil tapes, and the wrap rate of the wrap is not less than 25%;
  • the metal shielding layer is made of braided copper wire, the braided wire diameter is not greater than 0.15mm, and the braided density is 80% to 90%;
  • the signal core cable core is further wrapped with an inner sheath layer, and the inner sheath layer is then wrapped with the metal wrapping layer.
  • the auxiliary power wire core, signal core group, main power wire core, ground wire core and circulating cooling hose each have an even number; the radial cross section of the cable is circular; according to the wire diameter, the wire diameter is larger.
  • the functional cables are included, and the functional cables with the smaller diameter are arranged in sequence; the positions of the two functional cables with the closest diameter are axisymmetric along the straight line passing through the center of the circle.
  • the nominal wall thickness of the circulating cooling hose is at least 0.7mm.
  • the present invention proposes a new manufacturing method, dedicated to the cable, as follows:
  • a method for manufacturing a hollow cable the steps include:
  • A. Conductor It is composed of multiple strands of bare copper monofilaments; the diameter of bare copper monofilaments ranges from 0.1mm to 0.2mm; the pitch of bare copper monofilaments is not more than 18 times the outer diameter of the conductor after stranding The strand pitch of each bare copper wire is not more than 35 times the outer diameter of the strand after stranding; the bare copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the bare copper monofilament is not more than 0.001%, 20°C volume The resistivity is not greater than 0.01701 ⁇ .mm 2 /m;
  • the wire diameter of the conductors is different, and they are used as the main power core conductor and the ground core conductor respectively, and are reserved;
  • Copper foil conductor It is composed of copper foil butt-wound on the fiber surface, and then twisted with copper monofilament; copper monofilament is annealed bare copper monofilament, the oxygen content of copper in copper monofilament is not more than 0.001%, 20 The volume resistivity at °C is not more than 0.01701 ⁇ .mm 2 /m.
  • the wire diameter of the copper foil conductor is used as the auxiliary power line core copper conductor and the signal core group copper conductor, respectively, for backup;
  • auxiliary power core take the auxiliary power core copper conductor, and squeeze the thermosetting insulating material on the outside for backup;
  • signal core cable core with a pitch ratio of no more than 20 times;
  • the signal core cable core is overlaid with aluminum foil tape, and the wrap rate is not less than 25%; then outside the aluminum foil tape
  • Circulating cooling hose a hollow pipe extruded from thermoplastic elastomer material
  • the sheath layer is made by extruding the outer sheath material of the nonwoven fabric belt; the inner sheath is wrapped by a mesh structure composed of metal wire, the mesh structure is wrapped by the isolation layer, and the isolation layer is formed by extruding the sheath material Outer sheath.
  • step 1) during the twisting process, the traction speed of the conductor is 9.696 ⁇ 2m/min, and the traction speed is 10 to 15 levels;
  • the speed of 1+6 cage is (76 ⁇ 3)r/min
  • the speed of 12 coiling cage is (75.9 ⁇ 3)r/min
  • 18 coiling cage The rotation speed is (66 ⁇ 3)r/min
  • the outermost pitch of the stranded wire is not more than 160mm.
  • the cable core gap adopts non-hygroscopic high temperature resistant twisting type filling rope; the filling rope filling diameter is 94.0mm;
  • the cable twisting pitch range is 12 to 14 times the outer diameter of the core after stranding
  • the speed of the twisting cage of the twisting machine is 85 ⁇ 90r/min (preferably 92.2r/min), the traction speed is 4 ⁇ 5m/min (preferably 4m/min), and the speed of the winding head is 10 ⁇ 20r/min;
  • the overlap rate of overlapping wrapping with non-woven fabric tape is not less than 25%; when wrapping, the traction speed is 4 ⁇ 5m/min, the wrapping pitch is 40 ⁇ 5mm, the tension on the non-woven fabric belt is 40 ⁇ 45N (Preferably 40N); the wrapping direction is right and the wrapping tape thickness is 0.1mm.
  • thermosetting insulating material XLPO or EY
  • the temperature zones of the extruder are: 145 ⁇ 5°C in the first zone, 150 ⁇ 5°C in the second zone, 160 ⁇ 5°C in the third zone, 170 ⁇ 5°C in the fourth zone, and 180 ⁇ 5 in the fifth zone. 5°C; the temperature of each temperature zone of the machine head and neck is 185 ⁇ 5°C;
  • the first area is the feeding section
  • the second and third areas are the plasticizing section
  • the fourth and fifth areas are the homogenizing section
  • the irradiation energy is 1.2 ⁇ 2.1MEV
  • the beam current is 20mA ⁇ 26mA
  • the energy ratio is 1.2 ⁇ 2.0
  • the production line speed is 30 ⁇ 120m/min;
  • the connecting ribs and the outer insulating layer are made of the same material and are thermoplastic elastomers.
  • the mold is a co-extrusion mold.
  • a core and a mold sleeve are arranged on the head of the extruder.
  • the core diameter conductor Diameter +0.2mm;
  • the squeezing requirements for connecting ribs and external insulation are:
  • the temperature zones of the extruder are: 145 ⁇ 5°C in the first zone, 155 ⁇ 5°C in the second zone, 165 ⁇ 5°C in the third zone, 175 ⁇ 5°C in the fourth zone, and 185 ⁇ 5 in the fifth zone. 5°C; the temperature of each temperature zone of the machine head and neck is 190 ⁇ 5°C;
  • the first zone is the feeding section
  • the second and third zones are the plasticizing section
  • the fourth and fifth zones are the homogenizing section.
  • the outer sheath is obtained by extruding the sheath material with an extruder.
  • the first zone is the feeding section
  • the second and third zones are the plasticizing section
  • the fourth and fifth zones are the homogenizing section.
  • Discharge direction, discharge direction, body temperature zone 145 ⁇ 5°C in the first zone, 155 ⁇ 5°C in the second zone, 165 ⁇ 5°C in the third zone, 175 ⁇ 5°C in the fourth zone, 185 ⁇ 5°C in the fifth zone;
  • the temperature of each temperature zone of the head and neck is 195 ⁇ 5°C;
  • the first zone is the feeding section
  • the second and third zones are the plasticizing sections
  • the fourth and fifth zones are the homogenizing sections.
  • the signal core cable cores in each signal core group have different twisting pitches.
  • the specific design of the material and structure of this cable makes it fully charged within 15 minutes of charging time and has a range of 400km.
  • the weight and outer diameter of the cable are reduced.
  • the temperature rise of the charging heat is less than 15°C.
  • the application of this technology can solve the charging time of new energy vehicles in China at low cost. Long bottlenecks are conducive to the promotion and use of new energy vehicles.
  • the cable made by this method can meet the design requirements, and at the same time, the pass rate is high.
  • This cable can realize the cooling interface, cooling system, cooling material design, the main power insulated core conductor is reduced by 30%, the charging time is full within 15min, the cable weight and outer diameter are reduced, the application of this technology can solve China's new energy at low cost
  • the bottleneck problem of long vehicle charging time is conducive to the promotion and use of new energy vehicles.
  • FIG. 1 is a schematic view of the radial cross section of the cable of this embodiment
  • FIG. 2 is a radial cross-sectional schematic diagram of the outer insulation layer (including connecting ribs) of the main power core of the cable of this embodiment;
  • the main power core conductor 1 the inner power insulation layer 2 of the main power core, the hollow cavity 3, the outer insulation layer 4 of the main power core, the connecting ribs 5, the auxiliary power core copper conductor 6, the auxiliary power line Core insulation layer 7, ground core conductor 8, ground core insulation layer 9, signal core group copper conductor 10, signal core conductor surface insulation layer 11, gap filling 12 after the signal core is twisted, metal outside the signal core cable core
  • a hollow cable has a structure in which a cladding and an outer sheath are sequentially wrapped around a cable core; the cable core is composed of a circulating cooling hose and a plurality of cables stranded, and each cable The gap is filled with filling; each cable is:
  • Main power line core It is composed of the main power line core conductor which is sequentially wrapped with an inner insulation layer and an outer insulation layer, and a hollow cavity penetrating the entire cable is provided between the inner and outer insulation layers, and the hollow cavity constitutes a tubular channel;
  • hollow cavities which are symmetrical around the main power core; there are connecting ribs between adjacent hollow cavities; an anti-adhesive layer is provided between the inner insulating layer and the connecting rib; the anti-adhesive layer is the inner insulating layer Composition of anti-adhesion material applied on the outside;
  • Auxiliary power core It is composed of auxiliary power core copper conductor wrapped with auxiliary power core insulation layer;
  • Signal core group the signal core is composed of the copper conductor of the signal core group wrapped with an insulating layer, and a plurality of signal cores are twisted to form a signal core cable core, the signal core cable core is wrapped with a metal winding cladding, and the metal winding cladding is outside Wrapped with metal shielding layer; the gap between multiple signal cores is filled with filling;
  • Ground core is composed of the ground core conductor wrapped around the ground core insulation layer, and the ground core conductor is composed of multiple strands of copper wire;
  • the circulating cooling hose a hollow pipe extruded from a thermoplastic elastomer material.
  • the inner sheath of the cable core is also wrapped around the cladding layer, the inner sheath is wrapped with a mesh structure composed of metal wires, and the mesh structure has an isolation layer outside, and the isolation layer is wrapped with an outer sheath;
  • the filling rope material constituting the cable core is polypropylene filling rope
  • the wrapping layer outside the cable core is composed of a non-woven tape, the covering rate of the wrapping tape is not less than 5mm, the thickness of the non-woven tape is 0.1mm; the nominal thickness of the outer sheath is not less than 1.7mm.
  • the inner sheath is composed of thermoplastic elastomer sheath material extruded, the thickness of the inner sheath is not less than 0.5mm;
  • the mesh density of the mesh structure is not less than 80%.
  • the metal wire is tinned copper wire or bare copper wire. Among them, the resistivity of tinned copper wire at 20°C ⁇ 0.01780 ⁇ mm 2 /m, the resistivity of bare copper wire at 20°C ⁇ 0.017241 ⁇ mm 2 /m;
  • the elongation of the network structure is not less than 15%;
  • the isolation layer is made of environmentally friendly non-hygroscopic material, and the thickness of the isolation layer is not more than 0.1mm.
  • the outer surface of the outer insulation layer of the main power core is wrapped with a reinforced/explosion-proof layer;
  • the reinforced/explosion-proof layer is composed of a metal wire braid, a metal tape wrap or a fiber wire braid;
  • the main power line core conductor is also wrapped with a non-woven fabric wrapping layer, the wrapping rate of the wrapping is not less than 5mm, and the thickness of the non-woven fabric tape is 0.1mm;
  • the inner insulation layer is wrapped around the cladding layer, the nominal thickness of the inner insulation layer is 0.7mm at the thinnest;
  • the outer insulation layer is composed of thermoplastic elastomer insulation material, the nominal thickness of the outer insulation layer is not less than 1.0mm.
  • the anti-blocking layer is composed of an anti-blocking material applied to the surface of the inner insulating layer (the anti-blocking material may be an inorganic or organic polymer anti-blocking material in the prior art).
  • main power core conductor and the ground core conductor are the same, and they are all composed of stranded bare copper monofilament strands;
  • the diameter of bare copper monofilament is 0.1mm ⁇ 0.2mm; the twisted pitch of bare copper monofilament is not greater than 18 times the outer diameter of the conductor after stranding, and the strand pitch of each bare copper filament is not greater than the stranded strand 35 times the outer diameter;
  • the bare copper monofilament is annealed bare copper monofilament.
  • the oxygen content of copper in the bare copper monofilament is not greater than 0.001%, and the volume resistivity at 20°C is not greater than 0.01701 ⁇ .mm 2 /m.
  • the requirements of the copper conductor of the auxiliary power line and the copper conductor of the signal core group are the same, they are all copper foil conductors; the copper foil conductor is formed by butting the copper foil on the fiber surface and then twisting with the copper monofilament;
  • the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20°C is not more than 0.01701 ⁇ .mm 2 /m.
  • the pitch diameter ratio of multiple signal wire cores and filled rope strands to constitute the signal core cable core is not greater than 20 times;
  • the metal wrap layer is composed of overlapping aluminum foil tapes, and the wrap rate of the wrap is not less than 25%;
  • the metal shielding layer is made of braided copper wire, the braided wire diameter is not greater than 0.15mm, and the braided density is 80% to 90%;
  • the signal core cable core is further wrapped with an inner sheath layer, and the inner sheath layer is then wrapped with the metal wrapping layer.
  • the auxiliary power wire core, signal core group, main power wire core, ground wire core and circulating cooling hose each have an even number; the radial cross section of the cable is circular; according to the wire diameter, the wire diameter is larger.
  • the functional cables are included, and the functional cables with the smaller diameter are arranged in sequence; the positions of the two functional cables with the closest diameter are axisymmetric along the straight line passing through the center of the circle.
  • the nominal wall thickness of the circulating cooling hose is at least 0.7mm.
  • the requirements of the thermoplastic elastomer material used for the outer insulation layer (including connecting ribs) of the main power core include: halogen-free, flame retardant, and environmental protection; the tensile strength is not less than 10MPa; the elongation is not less than 300%;
  • the tensile strength is not less than 10MPa, the elongation is not less than 300%, and the change rate is not more than 25%;
  • the high temperature pressure indentation at 90 degrees Celsius is not more than 50%;
  • the insulation resistance constant is not less than 1 ⁇ 10 15 ⁇ cm, the hardness is not less than 85A (Shore), the dielectric strength is not less than 20kV/mm, the size of the outer insulation layer (including connecting ribs) is shown in Figure 2, and the unit in the figure is mm.
  • Hardness is not less than 90A (Shore), size deviation is not more than ⁇ 0.5mm, dielectric strength is not less than 20kV/mm, volume resistivity is 10 ⁇ 15 ⁇ cm,
  • Insulation resistance constant is not less than 3.67 at 90°C, not less than 3670 at 20°C,
  • the original mechanical properties tensile strength is not less than 15MPa, elongation at break is not more than 300%,
  • the mechanical properties, tensile strength and elongation at break are not more than ⁇ 30%.
  • the elongation is not more than 100%
  • the tear resistance is not less than 20N/mm
  • High temperature 90°C, 1h, thermal deformation is not more than 20%
  • Standard acid 20°C, 168h, tensile strength change rate is not more than ⁇ 25%,
  • the insulating material of the inner insulating layer is a thermosetting elastomer material, and the thermosetting insulating material needs to be cross-linked.
  • the temperature rating of the insulating material is 125 degrees, halogen-free, flame retardant, and environmental protection,
  • the original tensile strength is not less than 8MPa, the elongation is not less than 200%,
  • the change rate of tensile strength and elongation is not more than 30%.
  • -40°C low temperature stretching is not less than 30%, thermal shrinkage is not less than 2%,
  • the indentation of 90 degree high temperature pressure is not more than 50%
  • Insulation resistance constant is not less than 1*10 15 ⁇ cm
  • Hardness is not less than 85A (Shore).
  • Dielectric strength is not less than 20kV/mm
  • the hot elongation temperature is 250 degrees, the elongation is not more than 100%, the permanent deformation rate is not more than 25%, the nominal thickness of the insulation is the thinnest 0.7mm, and there is no upper limit.
  • the steps include:
  • A. Conductor It is composed of multiple strands of bare copper monofilaments; the diameter of bare copper monofilaments ranges from 0.1mm to 0.2mm; the pitch of bare copper monofilaments is not more than 18 times the outer diameter of the conductor after stranding The strand pitch of each bare copper wire is not more than 35 times the outer diameter of the strand after stranding; the bare copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the bare copper monofilament is not more than 0.001%, 20°C volume The resistivity is not greater than 0.01701 ⁇ .mm 2 /m;
  • the wire diameter of the conductors is different, and they are used as the main power core conductor and the ground core conductor respectively, and are reserved;
  • Copper foil conductor It is composed of copper foil butt-wound on the fiber surface, and then twisted with copper monofilament; copper monofilament is annealed bare copper monofilament, the oxygen content of copper in copper monofilament is not more than 0.001%, 20 The volume resistivity at °C is not more than 0.01701 ⁇ .mm 2 /m.
  • the wire diameter of the copper foil conductor is used as the auxiliary power line core copper conductor and the signal core group copper conductor, respectively, for backup;
  • auxiliary power core take the auxiliary power core copper conductor, and squeeze the thermosetting insulating material on the outside for backup;
  • signal core cable core with a pitch ratio of no more than 20 times;
  • the signal core cable core is overlaid with aluminum foil tape, and the wrap rate is not less than 25%; then outside the aluminum foil tape
  • Circulating cooling hose a hollow pipe extruded from thermoplastic elastomer material
  • the sheath layer is made by extruding the outer sheath material of the nonwoven fabric belt; the inner sheath is wrapped by a mesh structure composed of metal wire, the mesh structure is wrapped by the isolation layer, and the isolation layer is formed by extruding the sheath material Outer sheath.
  • step 1) during the twisting process, the traction speed of the conductor is 9.696 ⁇ 2m/min, and the traction speed is 10 to 15 levels;
  • the speed of 1+6 cage is (76 ⁇ 3)r/min
  • the speed of 12 coiling cage is (75.9 ⁇ 3)r/min
  • 18 coiling cage The rotation speed is (66 ⁇ 3)r/min
  • the outermost pitch of the stranded wire is not more than 160mm.
  • the cable core gap adopts non-hygroscopic high temperature resistant twisting type filling rope; the filling rope filling diameter is 94.0mm;
  • the cable twisting pitch range is 12 to 14 times the outer diameter of the core after stranding
  • the speed of the cage winding machine is 85 ⁇ 90r/min (preferably 92.2r/min in this example), the traction speed is 4 ⁇ 5m/min (preferably 4m/min in this example), and the speed around the bale head is 10 ⁇ 20r/ min;
  • the overlap rate of overlapping wrapping with non-woven fabric tape is not less than 25%; when wrapping, the traction speed is 4 ⁇ 5m/min, the wrapping pitch is 40 ⁇ 5mm, the tension on the non-woven fabric belt is 40 ⁇ 45N (40N is preferred in this example); the wrapping direction is right, and the wrapping tape thickness is 0.1 mm.
  • thermosetting insulating material XLPO or EY
  • the temperature zones of the extruder are: 145 ⁇ 5°C in the first zone, 150 ⁇ 5°C in the second zone, 160 ⁇ 5°C in the third zone, 170 ⁇ 5°C in the fourth zone, and 180 ⁇ 5 in the fifth zone. 5°C; the temperature of each temperature zone of the machine head and neck is 185 ⁇ 5°C;
  • the first area is the feeding section
  • the second and third areas are the plasticizing section
  • the fourth and fifth areas are the homogenizing section
  • the irradiation energy is 1.2 ⁇ 2.1MEV
  • the beam current is 20mA ⁇ 26mA
  • the energy ratio is 1.2 ⁇ 2.0
  • the production line speed is 30 ⁇ 120m/min;
  • the connecting ribs and the outer insulating layer are made of the same material and are thermoplastic elastomers.
  • the mold is a co-extrusion mold.
  • a core and a mold sleeve are arranged on the head of the extruder.
  • the core diameter conductor Diameter +0.2mm;
  • the squeezing requirements for connecting ribs and external insulation are:
  • the temperature zones of the extruder are: 145 ⁇ 5°C in the first zone, 155 ⁇ 5°C in the second zone, 165 ⁇ 5°C in the third zone, 175 ⁇ 5°C in the fourth zone, and 185 ⁇ 5 in the fifth zone. 5°C; the temperature of each temperature zone of the machine head and neck is 190 ⁇ 5°C;
  • the first zone is the feeding section
  • the second and third zones are the plasticizing section
  • the fourth and fifth zones are the homogenizing section.
  • the outer sheath is obtained by extruding the sheath material with an extruder.
  • the first zone is the feeding section
  • the second and third zones are the plasticizing section
  • the fourth and fifth zones are the homogenizing section.
  • Discharge direction, discharge direction, body temperature zone 145 ⁇ 5°C in the first zone, 155 ⁇ 5°C in the second zone, 165 ⁇ 5°C in the third zone, 175 ⁇ 5°C in the fourth zone, 185 ⁇ 5°C in the fifth zone;
  • the temperature of each temperature zone of the head and neck is 195 ⁇ 5°C;
  • the first zone is the feeding section
  • the second and third zones are the plasticizing sections
  • the fourth and fifth zones are the homogenizing sections.
  • thermosetting elastomer material of the insulating material on the surface of the copper conductor of the main power line conductor and the signal core group is an EVA substrate, which is combined with a toughening system, a flame retardant system, an anti-aging system and a lubricating system through physical and chemical modification.
  • the tear resistance is not less than 15N/mm, the water resistance passes the 80°C ⁇ 168 test requirement, the insulation hardness is not less than 90 Shore A, the insulation resistance constant is not less than 3670M ⁇ km at 20°C, the insulation tensile strength is not less than 10MPa, and the elongation at break Elongation is not less than 300%, after 158°C, 168h, the tensile strength change rate is not more than ⁇ 30%, the breaking elongation change rate is not more than ⁇ 30%, under -40°C, the breaking elongation is not less than 30 %, not less than 3.67 at 90°C, high temperature pressure indentation not more than 50% at 90°C; shrinkage not more than 4% at 130°C, no precipitation, no halogen, no red phosphorus, in line with environmental protection and REACH requirements.
  • the electron acceleration is used to complete the irradiation.
  • the insulation layer is sampled and the elongation at break is not greater than 100% and the permanent deformation rate is not greater than ⁇ 25% at 250 °C for 15 minutes.
  • the insulation material can be selected from environmentally friendly halogen-free flame-retardant thermoplastic elastomer.
  • the material uses elastomer as the base material, combined with the toughening system, flame-retardant system, anti-aging system and lubrication system through physical and chemical modification, the tear resistance is not Less than 15N/mm, water resistance passes 80°C ⁇ 168 test requirements, insulation hardness is not less than 85 Shore A, insulation resistance constant is not less than 3670M ⁇ km at 20°C, insulation tensile strength is not less than 10MPa, elongation at break is not less than 300%, after 135°C, after 168h, the tensile strength is not less than 10MPa, the change rate is not more than ⁇ 25%, the elongation at break is not less than 300%, the change rate is not more than ⁇ 25%, under -40°C, the elongation at break Elongation is not less than 30%, not less than 3.67 at 90°C, high temperature pressure inden
  • the filler material is a high-temperature resistant, twisted filler rope.
  • the main base material of the filler rope is polypropylene material, and different sizes of filler rope are placed for different gaps in the cable core; in addition, the filler material is insulated Under the condition of 125°C and 240h, the material will not be deformed, aging, decomposed, broken, etc., and still maintain the original good shape.
  • the sheath material is based on an elastomer, combined with a toughening system, a flame retardant system, an anti-aging system and a lubricating system, which are physically and chemically modified. It has good flexibility, oil resistance, wear resistance and UV resistance. , Resistance to hydrolysis, acid and alkali resistance, excellent flame retardancy, no precipitation, no halogen, no red phosphorus, 720h weather resistance, through a single vertical burning test, tear strength is not less than 20N/mm. Under the condition of 105°C and 4h, the slipping force of the cable remains above 500N.
  • the material (such as TPE) of the connecting ribs and the outer insulating layer is required to have high electrical properties, aging resistance, resistance to -40°C low temperature, resistance to hydrolysis, and resistance to chemical liquids.
  • the requirements of the sheath material (such as TPE or TPU) of the sheath layer are: high tear resistance, high wear resistance, water resistance, weather resistance, -40°C low temperature resistance, flame retardant, environmental protection, chemical liquid resistance, and UV protection.
  • ground core insulation layer, auxiliary line core, and signal line core insulation layer materials are: high hardness, high electrical resistance, -40°C low temperature resistance, aging resistance, flame retardancy, and thermosetting properties.
  • the signal core cable cores in each signal core group have different twisting pitches.
  • the two groups In order to avoid the interference of the signal core group, the two groups have different pitches.
  • the primary excellent rate of the product reaches 99.3%, and when it is relaxed within the range value, although a product that meets the quality requirements can be obtained, the primary excellent rate is mostly 98 ⁇ 99%.
  • the characteristics of this cable include:
  • the DC charging is shortened to 15 minutes, the electric vehicle can last 400 kilometers, and the cooling cable charging time is shortened by 90%.
  • the outer diameter of the cooling cable for high-power fast charging is controlled below 46mm, which is 25% lower than that of the finished cable of 400A DC charging cable.
  • the cooling cable for high-power fast charging is fully charged within 15 minutes to achieve an electric vehicle with a range of 400 kilometers and a temperature rise not exceeding 35°C.
  • the products submitted for inspection have undergone third-party type testing, and the volume resistivity of the insulation and sheath has been measured to 10 15 ⁇ .mm, which fills the high-voltage 10 9 ⁇ .mm of the silicone rubber of ISO International and GB national new energy vehicles.
  • the main power supply can meet the usage condition of 125°C. Meet the requirements of -40°C low temperature impact, -40°C low temperature winding, and -40°C low temperature tensile test.
  • This cable is rolled three times by the vehicle back and forth, applied voltage test, cooling cycle test, to meet repeated use.

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Abstract

一种用于新能源汽车充电的空心电缆制造方法，包括以下步骤：1）先制造导体和铜箔导体：2）各个线缆的制造：3）步骤2）制得的线缆以及循环冷却软管共同绞合成缆芯后，再绕包无纺布带；4）在无纺布带外挤包外护套料制得到护套层；内护套外包裹金属丝构成的网状结构，网状结构外包裹隔离层，隔离层外挤包护套料构成外护套。一种由该制造方法制得的空心电缆，其结构为：缆芯外依次包裹绕包层（17）和外护套（18）；缆芯由循环冷却软管（15）以及多根线缆绞合构成，在各根线缆的间隙内填有填充（16）；各根线缆分别为：主动力线芯、辅助电源线芯、信号芯组和地线芯。采用本方法制得的电缆，能满足设计要求，同时合格率高。

Description

一种用于新能源汽车充电的空心电缆制造方法及电缆 技术领域
本技术方案属于电缆技术领域，具体是一种空心电缆制造方法及电缆。
背景技术
目前新能源汽车常用的锂离子动力蓄电池存在着比能量低，一次充电续驶里程短的问题。因此，在目前动力电池不能提供更多续驶里程的情况下，如果能实现电池的充电快速化，从另一个角度来解决电动汽车续驶里程短的致命弱点。充电快速化成为发展的需求。同时三元催化技术、石墨烯技术的逐步成熟，动力蓄电池的比能量在不断提升，这就要求未来实现快速充电的同时，满足电池的大功率充电，实现充电的大功率的传递。
不管是混合动力汽车、纯电动汽车还是燃料电池汽车，都离不开高压电气系统。纯电动汽车和插电式混合动力汽车采取超过300V的高电压和几百安培大电流。电压的提升会提高充电零部件的电性能要求，成本较高,未来的电压预计最高提升到1000V。电流的提升成为大功率充电的必选途径。目前的电流最大可达成250A，充电的电缆已采用95mm 2的电缆，以保证实际使用的安全性。
当电流继续增加到400A时，传统的充电电缆的导体截面需要达到185mm 2或240mm 2，电缆单重大、外径大、使用不便。如果电流再上升到500A时，充电电缆的导体截面、外径需继续增大，带来了电缆重、不易弯曲、采购成本高、操作不便、生产加工难控制等缺点。
大功率充电的电流较大(由250A提升至400A及以上)，为解决电缆的发热现象，线束的直径随之变粗(50mm 2以上)，充电的操作性降低，方案的经济性降低。
故此必须要设计新的方案来解决大电流的发热问题，以较小的电缆来传递较大的电流。
大功率充电技术包括冷却系统技术、冷却电缆技术和冷却接口技术、电缆温升测试技术等方面。
发明内容
为了解决现有技术中存在的上述问题，本技术方案提出一种空心电缆及其制造方法，具体为：
一种空心电缆，其结构为：缆芯外依次包裹绕包层和外护套；所述缆芯由循环冷却软管以及多根线缆绞合构成，在各根线缆的间隙内填有填充；各根线缆分别为：
1)主动力线芯：由主动力线芯导体外依次包裹内绝缘层和外绝缘层构成，内外绝缘层之间设有贯穿整条电缆的中空腔体，该中空腔体构成管状通道；
所述中空腔体有多个，它们围绕主动力线芯对称；相邻中空腔体之间间隔有连接筋；内绝缘层与连接筋之间设有防粘连层；防粘连层是内绝缘层外涂抹防粘连材料构成；
2)辅助电源线芯：由辅助电源线芯铜导体外包裹辅助电源线芯绝缘层构成；
3)信号芯组：由信号芯组铜导体外包裹绝缘层构成信号线芯，多根信号线芯绞合构成信号芯缆芯，信号芯缆芯外包裹金属绕包层，金属绕包层外包裹金属屏蔽层；多根信号线芯的间隙内填有填充；
4)地线芯：由地线芯导体外包裹地线芯绝缘层构成地线芯，地线芯导体由多股铜丝组成；
所述循环冷却软管：由热塑性弹性体材料挤出构成的空心管道。
缆芯的绕包层外还包裹有内护套，内护套外包裹金属丝构成的网状结构，网状结构外有隔离层，隔离层外再包裹外护套；
构成缆芯的填充绳材料为聚丙烯填充绳；
缆芯外的绕包层是无纺布带绕包构成，绕包带搭盖率不小于5mm，无纺布带的厚度为0.1mm；外护套标称厚度不低于1.7mm。
内护套是由的热塑性弹性体护套料挤包构成，内护套的厚度不小于0.5mm；
网状结构的网孔密度不小于80％，金属丝是镀锡铜丝或裸铜丝，其中，镀锡铜丝20℃电阻率≤0.01780Ω·mm 2/m，裸铜丝20℃电阻率≤0.017241Ω·mm 2/m；
网状结构的伸长率不低于15％；
隔离层为环保非吸湿性材料构成，隔离层厚度不大于0.1mm。
所述主动力线芯中：
主动力线芯的外绝缘层外表面包裹有加强/防爆层；加强/防爆层是金属丝编织构成、金属带绕包构成或纤维丝编织构成；
主动力线芯导体外还包裹有无纺布带绕包构成的绕包层，绕包搭盖率不小于5mm，无纺布带的厚度为0.1mm；
绕包层外包裹有内绝缘层，内绝缘层的标称厚度最薄为0.7mm；
外绝缘层是由热塑性弹性体绝缘料挤包构成，外绝缘层的标称厚度不小于1.0mm。
所述主动力线芯中：
先挤包绝缘料构成内绝缘层；再在内绝缘层表面增加防粘连层，在防粘连层表面挤包外绝缘料构成连接筋和外绝缘层；
所述防粘连层是由涂抹在内绝缘层表面的防粘连材料构成(防粘连材料可以是现有技术中的是无机物或有机高分子防粘连材料)。
所述主动力线芯导体、地线芯导体的要求相同，它们都是由多股裸铜单丝绞合构成；
裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；
裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
所述辅助电源线芯铜导体和信号芯组铜导体的要求相同，它们都是铜箔导体；铜箔导体是铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；
铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
所述信号芯组中：
多根信号线芯以及填充绳绞合构成信号芯缆芯的节径比不大于20倍；
金属绕包层是由重叠绕包的铝箔带构成，绕包搭盖率不小于25％；
金属屏蔽层是由铜丝编织构成，编织丝直径不大于0.15mm，编织密度80％～ 90％；
所述信号芯缆芯还外包裹内护套层，内护套层外再包裹所述金属绕包层。
所述辅助电源线芯、信号芯组、主动力线芯、地线芯和循环冷却软管各有偶数根；所述电缆的径向截面是圆形；按照线径大小，线径较大的功能线缆在内，线径较小的功能线缆在外，依次排列；线径最接近的两功能线缆的位置是沿穿过圆心的直线成轴对称。
循环冷却软管的标称壁厚最小为0.7mm。
上述电缆在实际生产中遇到了问题：由于采用新的结构，采用传统生产工艺，或者是按照经验等在传统生产工艺上进行修正都无法生产出达到理论性能的电缆，甚至无法生产符合常规要求的电缆。为此，本发明创造提出一种新的制造方法，专用于该电缆，具体如下：
一种空心电缆的制造方法，步骤包括：
1)先制造导体和铜箔导体：
A、导体：是由多股裸铜单丝绞合构成；裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m；
导体的线径大小不同，分别作为主动力线芯导体和地线芯导体，备用；
B、铜箔导体：由铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
铜箔导体的线径大小，分别作为辅助电源线芯铜导体和信号芯组铜导体，备用；
2)各个线缆的制造：
2.1)制造主动力线芯：取主动力线芯导体，并在其外挤包热固性绝缘料，再涂涂抹防粘连材料，然后挤包连接筋和外绝缘层，最后，包裹加强/防爆层，备用；
2.2)制造辅助电源线芯：取辅助电源线芯铜导体，并在其外挤包热固性绝缘料，备用；
2.3)制造地线芯：取地线芯导体，并在其外挤包热固性绝缘料，备用；
2.4)制造信号芯组：取信号芯组铜导体，并在其外挤包热固性绝缘料，构成信号线芯；
多根信号线芯以及填充绳绞合构成信号芯缆芯，节径比不大于20倍；信号芯缆芯外重叠绕包铝箔带，绕包搭盖率不小于25％；再在铝箔带外包裹镀锡铜丝编织层作为金属屏蔽层，镀锡铜丝直径不大于0.15mm，编织密度80％～90％，备用；
2.5)循环冷却软管：由热塑性弹性体材料挤出构成的空心管道；
3)步骤2.1～2.5)制得的线缆以及循环冷却软管共同绞合成缆芯后，再绕包无纺布带；
4)在无纺布带外挤包外护套料制得到护套层；内护套外包裹金属丝构成的网状结构，网状结构外包裹隔离层，隔离层外挤包护套料构成外护套。
所述步骤1)中：绞制过程中，导体的牵引速度为9.696±2m/min，牵引转速为10～15级；
由1+6+12+18盘绞笼机绞制，1+6绞笼转速为(76±3)r/min，12盘绞笼转速为(75.9±3)r/min，18盘绞笼转速为(66±3)r/min，绞线最外层节距不大于160mm。
所述步骤3)中：
缆芯间隙采用非吸湿性耐高温加捻型填充绳；填充绳填充直径采用94.0mm；
成缆绞合节距范围是12～14倍线芯绞合后外径；
绞制过程中，绞笼机的绞笼转速85～90r/min(优选92.2r/min)，牵引速度4～5m/min(优选4m/min)，绕包头转速10～20r/min；
用无纺布带重叠绕包的搭盖率不小于25％；绕包时，牵引速度为4～5m/min，绕包节距为40±5mm，无纺布带上的张力为40～45N(优选40N)；绕包方向为右向，绕包带厚度为0.1mm。
所述步骤2.1)～2.4)中，根据相应绝缘层结构，采用相应的模具，挤包绝缘料，并冷却；所述步骤2.1)～2.4)中的热固性绝缘料(XLPO或EY)挤包要求为：
自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区150±5℃、三区160±5℃、四区170±5℃、五区180±5℃；机头和机颈的各个温区的温度都是185±5℃；
其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段；
绝缘料挤出后通过电子加速完成辐照,辐照能量1.2～2.1MEV，束流20mA～26mA，能量比1.2～2.0，生产线速度30～120m/min；
所述步骤2.1)中，连接筋和外绝缘层的材料相同，都是热塑性弹性体，其模具是共挤模具，在挤塑机的机头上配模芯、模套，模芯孔径＝导体直径+0.2mm；
连接筋和外绝缘的挤包要求为：
自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头和机颈的各个温区的温度都是190±5℃；
其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段。
所述步骤4)中，外护套是采用挤塑机挤包护套料得到，一区为入料段，二区、三区为塑化段，四区、五区为均化段自进料到出料方向，出料方向，机身温区为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头、机颈的各个温区的温度都是195±5℃；
一区为入料段，二区、三区为塑化段，四区、五区为均化段。
各根信号芯组中的信号芯缆芯的绞合节距不同。
本电缆通过材料、结构的特定设计，充电时间15min内充满，续航400km,电缆重量、外径降低，充电发热温升小于15℃，该技术的应用，可低成本的解决我国新能源汽车充电时间长的瓶颈问题，有利于新能源汽车的推广使用。
采用本方法制得的电缆，能满足设计要求，同时，合格率高。
本电缆可实现冷却接口，冷却系统，冷却材料设计，主动力绝缘线芯导体下降30％，充电时间15min内充满，电缆重量、外径降低，该技术的应用，可低成本的解决我国新能源汽车充电时间长的瓶颈问题，有利于新能源汽车的推广使用。
附图说明
图1是本实施例电缆的径向截面示意图，
图2是本实施例电缆的主动力线芯的外绝缘层(含连接筋)径向截面示意图；
图中：主动力线芯导体1、主动力线芯的内绝缘层2、中空腔体3、主动力线芯的外绝缘层4、连接筋5、辅助电源线芯铜导体6、辅助电源线芯绝缘层7、地线芯导体8、地线芯绝缘层9、信号芯组铜导体10、信号芯导体表面绝缘层11、信号线芯绞合后间隙填充12、信号芯缆芯外的金属绕包层13、信号芯缆芯外的金属屏蔽层14、循环冷却软管15、缆芯间隙填充16、缆芯外的绕包层17、外护套18。
具体实施方式
下面结合具体实施例对本技术方案进一步说明如下：
如图1，一种空心电缆，其结构为：缆芯外依次包裹绕包层和外护套；所述缆芯由循环冷却软管以及多根线缆绞合构成，在各根线缆的间隙内填有填充；各根线缆分别为：
1)主动力线芯：由主动力线芯导体外依次包裹内绝缘层和外绝缘层构成，内外绝缘层之间设有贯穿整条电缆的中空腔体，该中空腔体构成管状通道；
所述中空腔体有多个，它们围绕主动力线芯对称；相邻中空腔体之间间隔有连接筋；内绝缘层与连接筋之间设有防粘连层；防粘连层是内绝缘层外涂抹防粘连材料构成；
2)辅助电源线芯：由辅助电源线芯铜导体外包裹辅助电源线芯绝缘层构成；
3)信号芯组：由信号芯组铜导体外包裹绝缘层构成信号线芯，多根信号线芯绞合构成信号芯缆芯，信号芯缆芯外包裹金属绕包层，金属绕包层外包裹金属屏蔽层；多根信号线芯的间隙内填有填充；
4)地线芯：由地线芯导体外包裹地线芯绝缘层构成地线芯，地线芯导体由多股铜丝组成；
所述循环冷却软管：由热塑性弹性体材料挤出构成的空心管道。
缆芯的绕包层外还包裹有内护套，内护套外包裹金属丝构成的网状结构，网状结构外有隔离层，隔离层外再包裹外护套；
构成缆芯的填充绳材料为聚丙烯填充绳；
缆芯外的绕包层是无纺布带绕包构成，绕包带搭盖率不小于5mm，无纺布带的厚度为0.1mm；外护套标称厚度不低于1.7mm。
内护套是由的热塑性弹性体护套料挤包构成，内护套的厚度不小于0.5mm；
网状结构的网孔密度不小于80％，金属丝是镀锡铜丝或裸铜丝，其中，镀锡铜丝20℃电阻率≤0.01780Ω·mm 2/m，裸铜丝20℃电阻率≤0.017241Ω·mm 2/m；
网状结构的伸长率不低于15％；
隔离层为环保非吸湿性材料构成，隔离层厚度不大于0.1mm。
所述主动力线芯中：
主动力线芯的外绝缘层外表面包裹有加强/防爆层；加强/防爆层是金属丝编织构成、金属带绕包构成或纤维丝编织构成；
主动力线芯导体外还包裹有无纺布带绕包构成的绕包层，绕包搭盖率不小于5mm，无纺布带的厚度为0.1mm；
绕包层外包裹有内绝缘层，内绝缘层的标称厚度最薄为0.7mm；
外绝缘层是由热塑性弹性体绝缘料挤包构成，外绝缘层的标称厚度不小于1.0mm。
所述主动力线芯中：
先挤包绝缘料构成内绝缘层；再在内绝缘层表面增加防粘连层，在防粘连层表面挤包外绝缘料构成连接筋和外绝缘层；
所述防粘连层是由涂抹在内绝缘层表面的防粘连材料构成(防粘连材料可以是现有技术中的是无机物或有机高分子防粘连材料)。
所述主动力线芯导体、地线芯导体的要求相同，它们都是由多股裸铜单丝绞合构成；
裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；
裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
所述辅助电源线芯铜导体和信号芯组铜导体的要求相同，它们都是铜箔导体；铜箔导体是铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；
铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
所述信号芯组中：
多根信号线芯以及填充绳绞合构成信号芯缆芯的节径比不大于20倍；
金属绕包层是由重叠绕包的铝箔带构成，绕包搭盖率不小于25％；
金属屏蔽层是由铜丝编织构成，编织丝直径不大于0.15mm，编织密度80％～90％；
所述信号芯缆芯还外包裹内护套层，内护套层外再包裹所述金属绕包层。
所述辅助电源线芯、信号芯组、主动力线芯、地线芯和循环冷却软管各有偶数根；所述电缆的径向截面是圆形；按照线径大小，线径较大的功能线缆在内，线径较小的功能线缆在外，依次排列；线径最接近的两功能线缆的位置是沿穿过圆心的直线成轴对称。
循环冷却软管的标称壁厚最小为0.7mm。
实施例中，主动力线芯的外绝缘层(含连接筋)所用热塑性弹性体材料要求包括：无卤、阻燃、环保；抗张强度不小于10MPa；伸长率不小于300％；
135摄氏度、7天热空气老化，抗张强度不小于10MPa，伸长率不小于300％，变化率不超过25％；
-40摄氏度低温拉伸不小于30％，热收缩不小于2％；
90摄氏度高温压力压痕不大于50％；
绝缘电阻常数不低于1×10 15Ω·cm，硬度不小于85A(邵氏)，介电强度不低于20kV/mm，外绝缘层(含连接筋)尺寸见图2，图中单位为mm。
循环冷却软管的性能要求：
硬度不小于90A(邵氏)，尺寸偏差不大于±0.5mm，介电强度不小于20kV/mm，体积电阻率10^15Ω·cm，
绝缘电阻常数是90℃时不小于3.67，20℃时不小于3670，
原始机械性能抗张强度不小于15MPa，断裂伸长率不上于300％，
158℃、168h老化后机械性能，抗张强度和断裂伸长率变化率不大于±30％，
热延伸250℃、20min，
伸长率不大于100％，
永久变形率不大于15％，
抗撕不小于20N/mm，
150℃、1h,不开裂，耐磨不小于1万次，
高温90℃、1h，热变形不大于20％，
-40℃、4h，伸长率不小于30％，
150℃、1h，收缩不大于1％，
耐水：90℃、168h，抗张强度变化率不大于±25％，
耐水：20℃、168h，抗张强度变化率不大于±25％，
标准酸：20℃、168h，抗张强度变化率不大于±25％，
标准碱：20℃、168h，抗张强度变化率不大于±25％，
承压：90度条件下、1.0MPa、30min，管材不变形，不破裂；
承压：20度条件下、1.2MPa、30min，管材不变形，不破裂。
内绝缘层的绝缘料是热固性弹性体材料，热固性绝缘材料需要进行交联。绝缘料耐温等级为125度，无卤、阻燃、环保，
原始抗张强度不小于8MPa，伸长率不小于200％，
158度、7天热老化后，抗张强度、伸长率变化率不大于30％，
-40度低温拉伸不小于30％，热收缩不小于2％，
90度高温压力压痕不大于50％，
绝缘电阻常数不低于1*10 15Ω·cm，
硬度不小于85A(邵氏)，
介电强度不低于20kV/mm，
热延伸温度250度，伸长率不大于100％，永久变形率不大于25％，绝缘标称厚度最薄0.7mm，不设上限。
本例电缆的制造方法，步骤包括：
1)先制造导体和铜箔导体：
A、导体：是由多股裸铜单丝绞合构成；裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m；
导体的线径大小不同，分别作为主动力线芯导体和地线芯导体，备用；
B、铜箔导体：由铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
铜箔导体的线径大小，分别作为辅助电源线芯铜导体和信号芯组铜导体，备用；
2)各个线缆的制造：
2.1)制造主动力线芯：取主动力线芯导体，并在其外挤包热固性绝缘料，再涂涂抹防粘连材料，然后挤包连接筋和外绝缘层，最后，包裹加强/防爆层，备用；
2.2)制造辅助电源线芯：取辅助电源线芯铜导体，并在其外挤包热固性绝缘料，备用；
2.3)制造地线芯：取地线芯导体，并在其外挤包热固性绝缘料，备用；
2.4)制造信号芯组：取信号芯组铜导体，并在其外挤包热固性绝缘料，构成信号线芯；
多根信号线芯以及填充绳绞合构成信号芯缆芯，节径比不大于20倍；信号芯缆芯外重叠绕包铝箔带，绕包搭盖率不小于25％；再在铝箔带外包裹镀锡铜丝编织层作为金属屏蔽层，镀锡铜丝直径不大于0.15mm，编织密度80％～90％，备用；
2.5)循环冷却软管：由热塑性弹性体材料挤出构成的空心管道；
3)步骤2.1～2.5)制得的线缆以及循环冷却软管共同绞合成缆芯后，再绕包无纺布带；
4)在无纺布带外挤包外护套料制得到护套层；内护套外包裹金属丝构成的网状结构，网状结构外包裹隔离层，隔离层外挤包护套料构成外护套。
所述步骤1)中：绞制过程中，导体的牵引速度为9.696±2m/min，牵引转速为10～15级；
由1+6+12+18盘绞笼机绞制，1+6绞笼转速为(76±3)r/min，12盘绞笼转速为(75.9±3)r/min，18盘绞笼转速为(66±3)r/min，绞线最外层节距不大于160mm。
所述步骤3)中：
缆芯间隙采用非吸湿性耐高温加捻型填充绳；填充绳填充直径采用94.0mm；
成缆绞合节距范围是12～14倍线芯绞合后外径；
绞制过程中，绞笼机的绞笼转速85～90r/min(本例优选92.2r/min)，牵引速度4～5m/min(本例优选4m/min)，绕包头转速10～20r/min；
用无纺布带重叠绕包的搭盖率不小于25％；绕包时，牵引速度为4～5m/min，绕包节距为40±5mm，无纺布带上的张力为40～45N(本例优选40N)；绕包方向为右向，绕包带厚度为0.1mm。
所述步骤2.1)～2.4)中，根据相应绝缘层结构，采用相应的模具，挤包绝缘料，并冷却；所述步骤2.1)～2.4)中的热固性绝缘料(XLPO或EY)挤包要求为：
自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区150±5℃、三区160±5℃、四区170±5℃、五区180±5℃；机头和机颈的各个温区的温度都是185±5℃；
其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段；
绝缘料挤出后通过电子加速完成辐照,辐照能量1.2～2.1MEV，束流20mA～26mA，能量比1.2～2.0，生产线速度30～120m/min；
所述步骤2.1)中，连接筋和外绝缘层的材料相同，都是热塑性弹性体，其模具是共挤模具，在挤塑机的机头上配模芯、模套，模芯孔径＝导体直径+0.2mm；
连接筋和外绝缘的挤包要求为：
自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头和机颈的各个温区的温度都是190±5℃；
其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段。
所述步骤4)中，外护套是采用挤塑机挤包护套料得到，一区为入料段，二区、三区为塑化段，四区、五区为均化段自进料到出料方向，出料方向，机身温区为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头、机颈的各个温区的温度都是195±5℃；
一区为入料段，二区、三区为塑化段，四区、五区为均化段。
主动力线芯导体和信号芯组铜导体表面的绝缘料的热固性弹性体材料为EVA基材，配合配合增韧体系、阻燃体系、防老体系以及润滑体系经物理及化学改性而成，抗撕裂性能不小于15N/mm，耐水性通过80℃×168试验要求，绝缘硬度不小于90邵氏A，绝缘电阻常数20℃时不小于3670MΩ·km，绝缘抗张强度不小于10MPa、断裂伸长率不小于300％，158℃、168h后条件，抗张强度变化率不大于±30％，断裂伸长率变化率不大于±30％，-40℃条件下，断裂伸长率不小于30％，90℃时不小于3.67，90℃条件下高温压力压痕不大于50％；130℃条件下收缩不大于4％，不析出、无卤素、无红磷，符合环保及REACH要求。
绝缘料挤出后通过电子加速完成辐照,辐照后取绝缘层制样后，在250℃条件下、15min，断裂伸长率不大于100％，永久变形率不大于±25％；
绝缘材料可选环保型无卤阻燃热塑性弹性体，材料以弹性体为基材，配合增韧体系、阻燃体系、防老体系以及润滑体系经物理及化学改性而成，抗撕裂性能不小于15N/mm，耐水性通过80℃×168试验要求，绝缘硬度不小于85邵氏A，绝缘电阻常数20℃时不小于3670MΩ·km，绝缘抗张强度不小于10MPa、断裂伸长率不小于300％，135℃、168h后条件，抗张强度不小于10MPa、变化率不大于±25％，断裂伸长率不小于300％、变化率不大于±25％，-40℃条件下，断裂伸长率不小于30％，90℃时不小于3.67，90℃条件下高温压力压痕不大于50％；130℃条件下收缩不大于4％，不析出、无卤素、无红磷，符合环保及REACH要求。所述步骤3中，填充材料为耐高温、加捻型填充绳，该填充绳主要的基材为聚丙烯材料，针对缆芯中不同的间隙放置不同尺寸的填充绳；另外，该填充材料绝缘在125℃条件下、240h，材料可不发生变形、老化、分解、碎裂等现象，仍保持原有的良好形态。
步骤4)中，护套料是以弹性体为基材，配合增韧体系、阻燃体系、防老体系以及润滑体系经物理及化学改成，具有良好的柔顺性,耐油，耐磨、抗UV、耐 水解、耐酸碱，阻燃优越、不析出、无卤素、无红磷，耐720h气候，通过单根垂直燃烧试验，抗撕裂强度不小于20N/mm。在105℃条件下、4h，电缆的滑脱力仍保持500N以上。
连接筋和外绝缘层的材料(如TPE)要求为高电性、耐老化、耐-40℃低温、耐水解、耐化学液体。
所述护套层的护套料(如TPE或TPU)要求为：高抗撕、高耐磨、耐水、耐候、耐-40℃低温、阻燃、环保、耐化学液体、防紫外线。
所述地线芯绝缘层、辅助线芯、信号线芯绝缘层材料(如XLPO或EY)为：高硬度、高电性、耐-40℃低温、耐老化、阻燃和热固性。
各根信号芯组中的信号芯缆芯的绞合节距不同。为避免信号芯组干扰，两组绞合节距不同。
其中，上述工艺参数的选取中，当选择中间值以及优选值时候，产品的一次优秀率达到99.3％，而放宽在范围值内时候，虽然可以得到符合质量要求产品，但一次优秀率多在98～99％之间。
结果检测，本电缆的特点包括：
1)充电时间缩短
直流充电缩短至15min，实现电动汽车续航400公里，冷却电缆充电时间缩短90％。
2)电缆采购成本降低：电缆采购降本15％～20％。
3)电缆重量减轻、外径小
大功率快速充电用冷却电缆外径控制在46mm以下，相比较400A直流充电电缆成品电缆重量下降25％。
4)温升小
大功率快速充电用冷却电缆，15min内充满，实现电动汽车续航400公里，温升不超过35℃。
5)高电性
送检的产品经第三方型式检测，实测绝缘、护套的体积电阻率实测10 15Ω.mm，填补ISO国际、GB国家新能源汽车硅橡胶车内高压10 9Ω.mm。
6)耐高低温性能
主动力电源满足125℃工况使用。满足-40℃低温冲击、-40℃低温卷绕、-40℃低温拉伸试验要求。
7)阻燃试验：
满足GB/T18380.12单根燃烧。
8)耐化学试剂
同时满足ISO6722-1标准中的方法一、方法二、电池酸试验要求，满足工况要求。
9)耐车辆碾压
本电缆，经车辆往复3次碾压，施加电压测试、冷却循环测试，满足重复使用。

Claims (10)

  1. 一种用于新能源汽车充电的空心电缆制造方法，其特征是步骤包括：
    1)先制造导体和铜箔导体：
    A、导体：是由多股裸铜单丝绞合构成；裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m；
    导体的线径大小不同，分别作为主动力线芯导体和地线芯导体，备用；
    B、铜箔导体：由铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m；
    铜箔导体的线径大小，分别作为辅助电源线芯铜导体和信号芯组铜导体，备用；
    2)各个线缆的制造：
    2.1)制造主动力线芯：取主动力线芯导体，并在其外挤包热固性绝缘料，再涂涂抹防粘连材料，然后挤包连接筋和外绝缘层，最后，包裹加强/防爆层，备用；
    2.2)制造辅助电源线芯：取辅助电源线芯铜导体，并在其外挤包热固性绝缘料，备用；
    2.3)制造地线芯：取地线芯导体，并在其外挤包热固性绝缘料，备用；
    2.4)制造信号芯组：取信号芯组铜导体，并在其外挤包热固性绝缘料，构成信号线芯；
    多根信号线芯以及填充绳绞合构成信号芯缆芯，节径比不大于20倍；信号芯缆芯外重叠绕包铝箔带，绕包搭盖率不小于25％；再在铝箔带外包裹镀锡铜丝编织层作为金属屏蔽层，镀锡铜丝直径不大于0.15mm，编织密度80％～90％，备用；
    2.5)循环冷却软管：由热塑性弹性体材料挤出构成的空心管道；
    3)步骤2.1～2.5)制得的线缆以及循环冷却软管共同绞合成缆芯后，再绕包无纺布带；
    4)在无纺布带外挤包外护套料制得到护套层；内护套外包裹金属丝构成的网状结构，网状结构外包裹隔离层，隔离层外挤包护套料构成外护套。
  2. 根据权利要求1所述的制造方法，其特征是所述步骤3)中：
    缆芯间隙采用非吸湿性耐高温加捻型填充绳；填充绳填充直径采用94.0mm；
    成缆绞合节距范围是12～14倍线芯绞合后外径；
    绞制过程中，绞笼机的绞笼转速85～90r/min，牵引速度4～5m/min，绕包头转速10～20r/min；
    用无纺布带重叠绕包的搭盖率不小于25％；绕包时，牵引速度为4～5m/min，绕包节距为40±5mm，无纺布带上的张力为40～45N；绕包方向为右向，绕包带厚度为0.1mm。
  3. 根据权利要求1所述的制造方法，其所述步骤2.1)～2.4)中，根据相应绝缘层结构，采用相应的模具，挤包绝缘料，并冷却；所述步骤2.1)～2.4) 中的热固性绝缘料，挤包要求为：
    自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区150±5℃、三区160±5℃、四区170±5℃、五区180±5℃；机头和机颈的各个温区的温度都是185±5℃；
    其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段；
    绝缘料挤出后通过电子加速完成辐照,辐照能量1.2～2.1MEV，束流20mA～26mA，能量比1.2～2.0，生产线速度30～120m/min；
    所述步骤2.1)中，连接筋和外绝缘层的材料相同，都是热塑性弹性体，其模具是共挤模具，在挤塑机的机头上配模芯、模套，模芯孔径＝导体直径+0.2mm；
    连接筋和外绝缘的挤包要求为：
    自进料到出料方向，挤塑机机身温区分别为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头和机颈的各个温区的温度都是190±5℃；
    其中：一区为入料段，二区、三区为塑化段，四区、五区为均化段。
  4. 根据权利要求1所述的制造方法，其特征是所述步骤4)中，外护套是采用挤塑机挤包护套料得到，一区为入料段，二区、三区为塑化段，四区、五区为均化段自进料到出料方向，出料方向，机身温区为：一区145±5℃、二区155±5℃、三区165±5℃、四区175±5℃、五区185±5℃；机头、机颈的各个温区的温度都是195±5℃；
    一区为入料段，二区、三区为塑化段，四区、五区为均化段。
  5. 根据权利要求1所述的制造方法，其特征是各根信号芯组中的信号芯缆芯的绞合节距不同；
    所述步骤1)中：绞制过程中，导体的牵引速度为9.696±2m/min，牵引转速为10～15级；
    由1+6+12+18盘绞笼机绞制，1+6绞笼转速为(76±3)r/min，12盘绞笼转速为(75.9±3)r/min，18盘绞笼转速为(66±3)r/min，绞线最外层节距不大于160mm。
  6. 一种权利要求1～5任一方法制得的空心电缆，其特征是结构为：缆芯外依次包裹绕包层和外护套；所述缆芯由循环冷却软管以及多根线缆绞合构成，在各根线缆的间隙内填有填充；各根线缆分别为：
    1)主动力线芯：由主动力线芯导体外依次包裹内绝缘层和外绝缘层构成，内外绝缘层之间设有贯穿整条电缆的中空腔体，该中空腔体构成管状通道；
    所述中空腔体有多个，它们围绕主动力线芯对称；相邻中空腔体之间间隔有连接筋；内绝缘层与连接筋之间设有防粘连层；防粘连层是内绝缘层外涂抹防粘连材料构成；
    2)辅助电源线芯：由辅助电源线芯铜导体外包裹辅助电源线芯绝缘层构成；
    3)信号芯组：由信号芯组铜导体外包裹绝缘层构成信号线芯，多根信号线芯绞合构成信号芯缆芯，信号芯缆芯外包裹金属绕包层，金属绕包层外包裹金属屏蔽层；多根信号线芯的间隙内填有填充；
    4)地线芯：由地线芯导体外包裹地线芯绝缘层构成地线芯，地线芯导体由多股铜丝组成；
    所述循环冷却软管：由热塑性弹性体材料挤出构成的空心管道；
    缆芯的绕包层外还包裹有内护套，内护套外包裹金属丝构成的网状结构，网状结构外有隔离层，隔离层外再包裹外护套；
    主动力线芯的外绝缘层外表面包裹有加强/防爆层；加强/防爆层是金属丝编织构成、金属带绕包构成或纤维丝编织构成；
    主动力线芯导体外还包裹有无纺布带绕包构成的绕包层；绕包层外包裹有内绝缘层；
    所述信号芯缆芯还外包裹内护套层，内护套层外再包裹所述金属绕包层；
    所述辅助电源线芯、信号芯组、主动力线芯、地线芯和循环冷却软管各有偶数根；所述电缆的径向截面是圆形；按照线径大小，线径较大的功能线缆在内，线径较小的功能线缆在外，依次排列；线径最接近的两功能线缆的位置是沿穿过圆心的直线成轴对称。
  7. 根据权利要求1所述的空心电缆，其特征是
    构成缆芯的填充绳材料为聚丙烯填充绳；
    缆芯外的绕包层是无纺布带绕包构成，绕包带搭盖率不小于5mm，无纺布带的厚度为0.1mm；外护套标称厚度不低于1.7mm；
    内护套是由热塑性弹性体护套料挤包构成，内护套的厚度不小于0.5mm；
    网状结构的网孔密度不小于80％，金属丝是镀锡铜丝或裸铜丝，其中，镀锡铜丝20℃电阻率≤0.01780Ω·mm 2/m，裸铜丝20℃电阻率≤0.017241Ω·mm 2/m；
    网状结构的伸长率不低于15％；
    隔离层为环保非吸湿性材料构成，隔离层厚度不大于0.1mm；
    循环冷却软管的标称壁厚最小为0.7mm。
  8. 根据权利要求1所述的空心电缆，其特征是所述主动力线芯中：
    主动力线芯导体外的绕包层，绕包搭盖率不小于5mm，无纺布带的厚度为0.1mm；内绝缘层的标称厚度最薄为0.7mm；外绝缘层是由热塑性弹性体绝缘料挤包构成，外绝缘层的标称厚度不小于1.0mm。
  9. 根据权利要求1所述的空心电缆，其特征是所述主动力线芯导体、地线芯导体的要求相同，它们都是由多股裸铜单丝绞合构成；
    裸铜单丝的直径范围为0.1mm～0.2mm；裸铜单丝绞合的绞距不大于绞合后导体外径的18倍，每股裸铜丝的绞距不大于绞合后股线外径的35倍；
    裸铜单丝是退火裸铜单丝，裸铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m；
    所述辅助电源线芯铜导体和信号芯组铜导体的要求相同，它们都是铜箔导体；铜箔导体是铜箔对接疏绕在纤维表面后，再与铜单丝绞合构成；
    铜单丝是退火裸铜单丝，铜单丝中铜的氧含量不大于0.001％，20℃体积电阻率不大于0.01701Ω.mm 2/m。
  10. 根据权利要求1所述的空心电缆，其特征是
    所述信号芯组中：
    多根信号线芯以及填充绳绞合构成信号芯缆芯的节径比不大于20倍；
    金属绕包层是由重叠绕包的铝箔带构成，绕包搭盖率不小于25％；
    金属屏蔽层是由铜丝编织构成，编织丝直径不大于0.15mm，编织密度80％～90％。
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