WO2023160408A1 - 一种线缆连接结构 - Google Patents

一种线缆连接结构 Download PDF

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Publication number
WO2023160408A1
WO2023160408A1 PCT/CN2023/075353 CN2023075353W WO2023160408A1 WO 2023160408 A1 WO2023160408 A1 WO 2023160408A1 CN 2023075353 W CN2023075353 W CN 2023075353W WO 2023160408 A1 WO2023160408 A1 WO 2023160408A1
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WO
WIPO (PCT)
Prior art keywords
insulating layer
cable
welding
connection structure
shrinkable tube
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Application number
PCT/CN2023/075353
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English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车科技股份有限公司
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Publication of WO2023160408A1 publication Critical patent/WO2023160408A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H01R4/72—Insulation of connections using a heat shrinking insulating sleeve
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Definitions

  • the present application relates to the technical field of cable connection, and more particularly, to a cable connection structure.
  • the existing cables are usually copper cables.
  • copper cables due to the low stock of copper resources and high prices, it is necessary to use copper cables and aluminum cables together to meet the needs. and reduce costs.
  • the aluminum wire is affected by the layout space and cannot be matched with the existing connector.
  • the promotion and application of the aluminum wire are limited. Therefore, the connection technology of copper-aluminum conversion It has become an indispensable part of cable design in the future new energy vehicle wiring harness industry.
  • the purpose of this application is to provide a new technical solution for the cable connection structure.
  • a cable connection structure including a first cable, a second cable, and an adapter;
  • the first cable includes a first core and a first core covering the first core. Insulation layer, the first connection end is exposed after stripping part of the end of the first insulation layer of the first cable;
  • the second cable includes a second core and a second insulation covering the second core Layer, the second cable strips off part of the second insulating layer to expose the second connection end;
  • the first connection end and the second connection end are respectively electrically connected to the adapter to form a transfer
  • the connection part at least the outside of the connection part is covered with an inner heat shrinkable tube, a shielding layer and an outer heat shrinkable tube in sequence.
  • the outer surface of the transition component is further coated with conductive paste, and the inner heat-shrinkable tube covers the outer surface of the conductive paste.
  • the first wire core is a copper wire core
  • the second wire core is an aluminum wire core
  • resistance welding ultrasonic welding, plasma welding, friction welding, arc welding, laser welding, electron beam welding, pressure diffusion
  • ultrasonic welding ultrasonic welding
  • plasma welding friction welding
  • arc welding laser welding
  • electron beam welding pressure diffusion
  • pressure diffusion pressure diffusion
  • the transfer joint is formed by cutting or bending or stamping a plate, and the plate is provided with a coating at least in the welding area, and the material of the coating is nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, Gold, silver, zinc, pewter, silver antimony, palladium, palladium nickel, graphite silver, graphene silver, hard silver or silver gold zirconium.
  • the shielding layer is copper foil tape or aluminum foil tape.
  • the first insulating layer includes a first inner insulating layer and a first outer insulating layer, and a first shielding layer is also arranged between the first inner insulating layer and the first outer insulating layer;
  • the The second insulating layer includes a second inner insulating layer and a second outer insulating layer, and a second shielding layer is arranged between the second inner insulating layer and the second outer insulating layer.
  • the first shielding layer and the second shielding layer are respectively overlapped with the shielding layer, and along the axial direction, the length of the overlapping area is greater than 10% of the total length of the shielding layer.
  • the first outer insulating layer and the second outer insulating layer are respectively overlapped with the outer heat-shrinkable tube, and along the axial direction, the length of the overlapping area is longer than that of the outer heat-shrinkable tube 10% of the total length.
  • the outer heat-shrinkable tube is a double-walled heat-shrinkable tube.
  • the copper wire and aluminum wire conversion connection technology of this application solves the problems of reducing the weight of the wire harness, high cost and limited space.
  • the copper wire and the aluminum wire are connected through the adapter joint, and the copper wire and the aluminum wire can be realized according to the actual situation.
  • Flexible combination use not only retains the advantages of copper wires, but also reduces the weight of the entire high-voltage wire harness, and solves the space limitation problem of terminals. It has simple structure, reliable performance, and a wider range of applications.
  • Fig. 1 is the front view of the cable connection structure of the present application
  • Fig. 2 is a schematic diagram of the cable connection structure of the present application.
  • Fig. 3 is a cross-sectional view of the cable connection structure of the present application.
  • a cable connection structure includes a first cable 2, a second cable 3 and an adapter 1;
  • the first cable 2 includes a first core 201 and the first insulating layer covering the first core 201, the first cable 2 is stripped off part of the end of the first insulating layer to expose the first connection end;
  • the cable 3 includes a second core 301 and a second insulating layer covering the second core 301, and the second cable 3 exposes a second connection end after stripping off part of the second insulating layer;
  • the first insulating layer and the second insulating layer are not shown in the figure, specifically, only one insulating layer is coated on the outside of the first core 201, that is, the first insulating layer; the second core 301 is coated with an insulating layer, That is the second insulating layer.
  • the material of the first insulation layer and the second insulation layer is PVC, which ensures the insulation performance on the one hand, and also has waterproof performance, wear resistance and hardness on the other hand.
  • the insulation material of the cable can also be rubber, TPE, XPE, PP, One or more of XLPE, FEP, ETFE, TPR and TPFE.
  • the first connection end and the second connection end are respectively electrically connected to the adapter 1 to form an adapter part; at least the outside of the adapter part is covered with an inner heat shrinkable tube 4, a shielding layer 5 and an outer heat shrinkable tube in sequence. shrink tube6.
  • the first cable 2 is composed of a first core 201 covered with a first insulation layer on the outside of the first core 201, and the second cable 3 is covered by a second core 301 The second insulating layer outside the second core 301 is formed, and the first cable 2 and the second cable 3 are connected through the adapter 1 .
  • the adapter 1 is connected to the first connection end and the second connection end respectively, the problem of the space limitation of the connection between the first cable 2 and the second cable 3 is solved, and the structure is simple, the performance is reliable, and the application range is wide.
  • the inner heat-shrinkable tube 4, the shielding layer 5 and the outer heat-shrinkable tube 6 are sequentially arranged outside the adapter part, which can not only ensure the structural stability of the connection between the adapter 1 and the first connection end and the second connection end, but also effectively shield The electromagnetic interference generated by the internal cables on the external signal lines.
  • the inner heat-shrinkable tube 4 is specifically a single-wall heat-shrinkable tube, which can be heat-shrinked with a heat gun to ensure 100% insulation of the connecting parts.
  • the outer surface of the adapter component is further coated with a conductive paste 7
  • the inner heat-shrinkable tube 4 is coated on the outer surface of the conductive paste 7 .
  • Coating the conductive paste 7 on the outer surface of the adapter part can reduce the heat generation of the adapter 1, reduce the contact resistance of the connecting part, and make the connection between the first connection end and the second connection end and the adapter 1 be stable during long-term operation. Can maintain good electrical conductivity.
  • the gap between copper wire and aluminum wire can be filled with solder welding, which can isolate the corrosion of air and water, enhance the pulling force and tearing force of the welding place, and the alloying of the connection interface can effectively prevent The occurrence of galvanic corrosion in copper-aluminum contact.
  • the first wire core 201 is a copper wire core
  • the second wire core 301 is an aluminum wire core
  • the first wire core 201 and the second wire core 301 are respectively a copper wire core and an aluminum wire core, which may be a single-core wire or a multi-core wire, and may be made of a rigid material or a flexible material.
  • the conversion connection technology of this application solves the problems of reducing the weight of the wiring harness, high cost and space limitation.
  • the copper wire and the aluminum wire are connected through the conversion head, and the flexible combination of the copper wire and the aluminum wire can be realized according to the actual situation.
  • the advantages of copper wire are not only reduced, but also the weight of the whole wire harness is reduced, and the problem of space limitation of the terminal is solved.
  • first connection end and/or the second connection end and the adapter joint 1 are welded by resistance welding, ultrasonic welding, plasma welding, friction welding, arc welding, laser welding, or electron beam welding. , pressure diffusion welding, magnetic induction welding one of welding forming.
  • the resistance welding method refers to a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat from the contact resistance to achieve welding.
  • the friction welding method refers to the method of welding by using the heat generated by the friction of the contact surface of the workpiece as the heat source to cause the workpiece to undergo plastic deformation under pressure.
  • the ultrasonic welding method is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form fusion between molecular layers.
  • the arc welding method refers to using the arc as a heat source and using the physical phenomenon of air discharge to convert electrical energy into thermal energy and mechanical energy required for welding, so as to achieve the purpose of connecting metals.
  • the main methods are electrode arc welding, submerged arc welding, and gas protection. welding etc.
  • Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
  • the electron beam welding method refers to the use of accelerated and focused electron beams to bombard the welding surface placed in a vacuum or non-vacuum, so that the workpiece to be welded is melted to achieve welding.
  • the pressure welding method is a method of applying pressure to the weldment, so that the joint surface is in close contact to produce a certain plastic deformation to complete the welding.
  • the diffusion welding method refers to a solid-state welding method in which the workpiece is pressurized at high temperature without visible deformation and relative movement.
  • the magnetic induction welding method is that two workpieces to be welded are subjected to an instantaneous high-speed collision under the action of a strong pulsed magnetic field. Form a stable metallurgical bond. It is a kind of solid-state cold welding, which can weld conductive metals with similar or dissimilar properties together.
  • connection methods an appropriate connection method or combination of connection methods can be selected according to the actual use environment to realize effective electrical connection.
  • the adapter 1 is formed by cutting or bending or stamping a plate, and the plate is provided with a coating at least in the welding area, and the material of the coating is nickel, cadmium, manganese, zirconium, cobalt, tin, Titanium, chromium, gold, silver, zinc, pewter, silver antimony, palladium, palladium nickel, graphite silver, graphene silver, hard silver or silver gold zirconium.
  • Providing a plating layer in the welding area can effectively improve the corrosion resistance and electrical conductivity of the connection between the adapter joint 1 and the first connection end and the second connection end, and can prolong the service life of the adapter parts.
  • the shielding layer 5 is copper foil tape or aluminum foil tape.
  • the shielding layer 5 can effectively shield the electromagnetic interference generated by the external signal lines after the internal cables are energized. At the same time, it can isolate the damage of electromagnetic waves to the human body.
  • copper foil tape or aluminum foil tape is used to spirally wrap around the outer side of the inner heat-shrinkable tube 4 .
  • the first insulating layer includes a first inner insulating layer 202 and a first outer insulating layer 204, and the first inner insulating layer 202 and the first outer insulating layer 204 There is also a first shielding layer 203 between them;
  • the second insulating layer includes a second inner insulating layer 302 and a second outer insulating layer 304, the second inner insulating layer 302 and the second outer insulating layer 304 A second shielding layer 303 is also provided between them.
  • the first shielding layer 203 and the second shielding layer 303 overlap with the shielding layer 5 respectively, and along the axial direction, the length of the overlapping area is greater than 10% of the total length of the shielding layer 5 .
  • the overlapping of the shielding layer 5 is to ensure 100% shielding effect. Specifically, use copper foil tape or aluminum foil tape to spirally wrap around the outside of the inner heat shrinkable tube 4, and overlap with the first shielding layer 203 and the second shielding layer 303 respectively, and the length of the overlapped overlapping area is greater than that of the shielding layer 5 10% of the total length, further, the length of the overlapped overlapping area is 10%-15% of the total length of the shielding layer 5, specifically 10%, 12%, 14%, 15%.
  • the first outer insulating layer 204 and the second outer insulating layer 304 are respectively overlapped with the outer heat shrinkable tube 6 , and along the axial direction, the overlapping area is longer than the outer heat shrinkable tube 6 10% of the total length.
  • the overlapping of the outer heat shrinkable tube 6 is to ensure waterproofing and sealing, and to protect the copper-aluminum conversion high-voltage wire harness from external air and water corrosion. Further, the length of the overlapped overlapping area is 10% of the total length of the outer heat shrinkable tube- 15%, specifically 10%, 12%, 14%, 15%.
  • the outer heat-shrinkable tube 6 is a double-walled heat-shrinkable tube.
  • the outer heat-shrinkable tube 6 is heat-shrinkable with a double-walled heat-shrinkable tube.
  • the outer layer material has the advantages of insulation, corrosion resistance, wear resistance, etc.
  • the inner layer material has the advantages of low melting point, waterproof, sealing, and high adhesiveness, etc., to protect the transfer parts from Affected by external air and water corrosion, the conversion structure of the transfer part is safer and more reliable.
  • a heat gun is used to fasten and bond the heat-shrinkable inner layer hot melt adhesive.

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Abstract

本申请公开了一种线缆连接结构，包括第一线缆、第二线缆和转接接头；所述第一线缆包含第一线芯和包覆所述第一线芯的第一绝缘层，所述第一线缆剥离所述第一绝缘层的部分端部后裸露出第一连接端；所述第二线缆包含第二线芯和包覆所述第二线芯的第二绝缘层，所述第二线缆剥离所述第二绝缘层的部分端部后裸露出第二连接端；所述第一连接端和所述第二连接端分别与转接接头电连接后形成转接部件；至少在所述转接部件外部依次包覆有内热缩管、屏蔽层和外热缩管。该结构解决了端子的空间限制问题，结构简单、性能可靠、应用范围广泛。

Description

一种线缆连接结构
相关申请
本申请要求2022年02月22日递交的、申请号为CN202220356890.X、专利名称为“一种线缆连接结构”的中国实用新型专利的优先权，该专利的所有内容在此全部引入。
技术领域
本申请涉及线缆连接技术领域，更具体地，涉及一种线缆连接结构。
背景技术
线缆在新能源电动汽车的应用越来越广泛，现有使用的线缆通常为铜线缆，但是由于铜资源存量少、价格高等原因，需要铜线缆和铝线缆一起使用来满足需要和降低成本。使用同等载流量的铝导线，不仅成本和自身重量低于铜导线，而且，铝的资源储备也远远高于铜。铝导线受到布置空间的影响，无法和现有连接器匹配，同时由于新开发连接器周期长，成本高的限制等因素的影响，限制了铝导线的推广和应用，所以铜铝转换的连接技术成为了线缆设计在未来新能源汽车线束行业不可或缺的一部分。
实用新型内容
本申请的目的是提供一种线缆连接结构的新技术方案。
根据本申请提供了一种线缆连接结构，包括第一线缆、第二线缆和转接接头；所述第一线缆包含第一线芯和包覆所述第一线芯的第一绝缘层，所述第一线缆剥离所述第一绝缘层的部分端部后裸露出第一连接端；所述第二线缆包含第二线芯和包覆所述第二线芯的第二绝缘层，所述第二线缆剥离所述第二绝缘层的部分端部后裸露出第二连接端；所述第一连接端和所述第二连接端分别与转接接头电连接后形成转接部件；至少在所述转接部件外部依次包覆有内热缩管、屏蔽层和外热缩管。
可选地，所述转接部件的外表面还涂覆有导电膏，所述内热缩管包覆在所述导电膏的外表面。
可选地，所述第一线芯为铜线芯，所述第二线芯为铝线芯。
可选地，所述第一连接端和/或所述第二连接端与所述转接接头采用电阻焊接、超声波焊接、等离子焊接、摩擦焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接其中一种焊接成型。
可选地，所述转接接头为板材切割或折弯或冲压成型，所述板材至少在焊接区域设置镀层，所述镀层材质为镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银、硬银或银金锆合金。
可选地，所述屏蔽层为铜箔胶带或铝箔胶带。
可选地，所述第一绝缘层包括第一内绝缘层和第一外绝缘层，所述第一内绝缘层和所述第一外绝缘层之间还设置有第一屏蔽层；所述第二绝缘层包括第二内绝缘层和第二外绝缘层，所述第二内绝缘层和所述第二外绝缘层之间还设置有第二屏蔽层。
可选地，所述第一屏蔽层和所述第二屏蔽层分别与所述屏蔽层搭接，沿轴向方向，所述搭接重叠区域的长度大于所述屏蔽层总长度的10％。
可选地，所述第一外绝缘层和所述第二外绝缘层分别与所述外热缩管搭接，沿轴向方向，所述搭接重叠区域的长度大于所述外热缩管总长度的10％。
可选地，所述外热缩管为双壁热缩管。
本申请具有以下技术效果：
本申请铜线和铝线转换连接技术解决了减轻线束重量、成本居高不下和受空间限制的问题，通过转接接头将铜导线和铝导线相连接，能够实现铜线和铝线根据实际情况灵活组合使用，即保留了铜线的优点，又减轻了整条高压线束的重量，解决了端子的空间限制问题，结构简单、性能可靠、应用范围更为广泛。
通过以下参照附图对本申请的示例性实施例的详细描述，本申请的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本申请的实施例，并且连同其说明一起用于解释本申请的原理。
图1为本申请线缆连接结构主视图；
图2为本申请线缆连接结构示意图；
图3为本申请线缆连接结构剖视图。
【附图标记说明】：
1、转接接头；2、第一线缆；3、第二线缆；4、内热缩管；5、屏蔽层；6、外热缩管；7、导电膏；201、第一线芯；202、第一内绝缘层；203、第一屏蔽层；204、第一外绝缘层；301、第二线芯；302、第二内绝缘层；303、第二屏蔽层；304、第二外绝缘层。
具体实施方式
现在将参照附图来详细描述本申请的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
在一实施方式中，如图1-图3所示，一种线缆连接结构，包括第一线缆2、第二线缆3和转接接头1；所述第一线缆2包含第一线芯201和包覆所述第一线芯201的第一绝缘层，所述第一线缆2剥离所述第一绝缘层的部分端部后裸露出第一连接端；所述第二线缆3包含第二线芯301和包覆所述第二线芯301的第二绝缘层，所述第二线缆3剥离所述第二绝缘层的部分端部后裸露出第二连接端；
第一绝缘层和第二绝缘层图中未示出，具体的可以为第一线芯201外只包覆一层绝缘层，即第一绝缘层；第二线芯301包覆一层绝缘层，即第二绝缘层。
第一绝缘层和第二绝缘层的材质为PVC，一方面保证绝缘性能，另一方面还具有防水性能，耐磨性和硬度，电缆的绝缘的材质还可以是橡胶，TPE、XPE、PP、XLPE、FEP、ETFE、TPR和TPFE的一种或多种。
所述第一连接端和所述第二连接端分别与转接接头1电连接后形成转接部件；至少在所述转接部件外部依次包覆有内热缩管4、屏蔽层5和外热缩管6。
本申请提供的一种线缆连接结构，第一线缆2由第一线芯201包覆在第一线芯201外部的第一绝缘层组成，第二线缆3由第二线芯301包覆在第二线芯301外部的第二绝缘层组成，第一线缆2和第二线缆3通过转接接头1连接。
通过转接接头1与第一连接端和第二连接端分别连接的方案，解决了第一线缆2和第二线缆3连接受到空间限制的问题，结构简单、性能可靠、应用范围广泛。
所述转接部件外部依次设置内热缩管4、屏蔽层5和外热缩管6不仅能够保证转接接头1与第一连接端和第二连接端连接的结构稳定性，还能够有效的屏蔽内部线缆通电后对外部信号线产生的电磁干扰。
内热缩管4具体为单壁热缩管，具体可以靠热风枪热缩成型，能够保证转接部件100％绝缘。
在一实施方式中，如图2和图3所示，所述转接部件的外表面还涂覆有导电膏7，所述内热缩管4包覆在所述导电膏7的外表面。
导电膏7涂敷在转接部件的外表面能够减少转接接头1的发热，降低连接部件的接触电阻，使第一连接端和第二连接端分别与转接接头1的连接在长期的运行中能保持良好的导电性能。
在铜铝转换连接过程中，铜线和铝线之间间隙处可以填充焊料焊接，隔绝空气和水的腐蚀，增强了焊接处的拉拔力与撕裂力，连接界面的合金化能有效防止铜铝接触电偶腐蚀的发生。
在一实施方式中，所述第一线芯201为铜线芯，所述第二线芯301为铝线芯。
第一线芯201和第二线芯301分别为铜线芯和铝线芯，可以是单芯线也可以是多芯线，可以是刚性材质也可以是柔性材质。本申请的转换连接技术解决了减轻线束重量、成本较高和受空间限制的问题，通过转换头将铜线和铝线相连接，能够实现铜线和铝线根据实际情况灵活组合使用，即保留了铜线的优点，又减轻了整条线束的重量，解决了端子的空间限制问题。
在一实施方式中，所述第一连接端和/或所述第二连接端与所述转接接头1采用电阻焊接、超声波焊接、等离子焊接、摩擦焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接其中一种焊接成型。
电阻焊接方式，是指一种利用强大电流通过电极和工件间的接触点，由接触电阻产生热量而实现焊接的一种方法。
摩擦焊接方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
超声波焊接方式，是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。
弧焊方式，是指以电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的，主要方法有焊条电弧焊、埋弧焊、气体保护焊等。
激光焊接方式，是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
电子束焊接方式，是指利用加速和聚焦的电子束轰击置于真空或非真空中的焊接面，使被焊工件熔化实现焊接。
压力焊接方式，是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
扩散焊方式，指将工件在高温下加压，但不产生可见变形和相对移动的固态焊方法。
磁感应焊接方式，是两个被焊工件在强脉冲磁场作用下，产生瞬间高速碰撞，材料表层在很高的压力波作用下，使两种材料的原子在原子间距离内相遇，从而在界面上形成稳定的冶金结合。是固态冷焊的一种，可以将属性相似或不相似的传导金属焊接在一起。
通过上述连接方式，可以根据实际的使用环境，选择合适的连接方式或者连接方式组合，实现有效的电性连接。
在一实施方式中，所述转接接头1为板材切割或折弯或冲压成型，所述板材至少在焊接区域设置镀层，所述镀层的材质为镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银、硬银或银金锆合金。
在焊接区域设置镀层能有效的提高转接接头1与第一连接端和第二连接端连接处的耐腐蚀性和导电性能，能够延长转接部件的使用寿命。
在一实施方式中，所述屏蔽层5为铜箔胶带或铝箔胶带。
屏蔽层5可以有效的屏蔽内部线缆通电后对外部信号线产生的电磁干扰。同时能够隔离电磁波对人体的伤害。具体的，使用铜箔胶带或铝箔胶带单面螺旋环绕在内热缩管4的外侧。
在一实施方式中，如图3所示，所述第一绝缘层包括第一内绝缘层202和第一外绝缘层204，所述第一内绝缘层202和所述第一外绝缘层204之间还设置有第一屏蔽层203；所述第二绝缘层包括第二内绝缘层302和第二外绝缘层304，所述第二内绝缘层302和所述第二外绝缘层304之间还设置有第二屏蔽层303。
所述第一屏蔽层203和所述第二屏蔽层303分别与所述屏蔽层5搭接，沿轴向方向，所述搭接重叠区域的长度大于所述屏蔽层5总长度的10％。
屏蔽层5搭接是为了保证100％屏蔽效果。具体的，使用铜箔胶带或铝箔胶带单面螺旋环绕在内热缩管4的外侧，并分别与第一屏蔽层203和第二屏蔽层303搭接，搭接的重叠区域的长度大于屏蔽层5总长度的10％，进一步地，搭接的重叠区域的长度为屏蔽层5总长度的10％-15％，具体的可以为10％、12％、14％、15％。
所述第一外绝缘层204和所述第二外绝缘层304分别与所述外热缩管6搭接，沿轴向方向，所述搭接重叠区域的长度大于所述外热缩管6总长度的10％。
外热缩管6搭接是为了保证防水和密封，保护铜铝转换高压线束不受外界空气和水腐蚀影响，进一步地，搭接的重叠区域的长度为外热缩管总长度的10％-15％，具体的可以为10％、12％、14％、15％。
所述外热缩管6为双壁热缩管。
外热缩管6采用双壁热缩管热缩成型，外层材料具有绝缘防腐、耐磨等优点，内层材料具有低熔点、防水、密封和高粘接性等优点，保护转接部件不受外界空气和水腐蚀影响，使转接部件的转换结构更安全可靠。具体的，外热缩管6与第一外绝缘层204和第二外绝缘层304分别搭接后，使用热风枪对热缩内层热熔胶进行紧固粘接。
虽然已经通过例子对本申请的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本申请的范围。本领域的技术人员应该理解，可在不脱离本申请的范围和精神的情况下，对以上实施例进行修改。本申请的范围由所附权利要求来限定。

Claims (10)

  1. 一种线缆连接结构，其特征在于，包括第一线缆、第二线缆和转接接头；
    所述第一线缆包含第一线芯和包覆所述第一线芯的第一绝缘层，所述第一线缆剥离所述第一绝缘层的部分端部后裸露出第一连接端；
    所述第二线缆包含第二线芯和包覆所述第二线芯的第二绝缘层，所述第二线缆剥离所述第二绝缘层的部分端部后裸露出第二连接端；
    所述第一连接端和所述第二连接端分别与转接接头电连接后形成转接部件；
    至少在所述转接部件外部依次包覆有内热缩管、屏蔽层和外热缩管。
  2. 根据权利要求1所述的线缆连接结构，其特征在于，所述转接部件的外表面还涂覆有导电膏，所述内热缩管包覆在所述导电膏的外表面。
  3. 根据权利要求1所述的线缆连接结构，其特征在于，所述第一线芯为铜线芯，所述第二线芯为铝线芯。
  4. 根据权利要求1所述的线缆连接结构，其特征在于，所述第一连接端和/或所述第二连接端与所述转接接头采用电阻焊接、超声波焊接、等离子焊接、摩擦焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接其中一种焊接成型。
  5. 根据权利要求1所述的线缆连接结构，其特征在于，所述转接接头为板材切割或折弯或冲压成型，所述板材至少在焊接区域设置镀层，所述镀层材质为镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银、硬银或银金锆合金。
  6. 根据权利要求1所述的线缆连接结构，其特征在于，所述屏蔽层为铜箔胶带或铝箔胶带。
  7. 根据权利要求1所述的线缆连接结构，其特征在于，所述第一绝缘层包括第一内绝缘层和第一外绝缘层，所述第一内绝缘层和所述第一外绝缘层之间还设置有第一屏蔽层；
    所述第二绝缘层包括第二内绝缘层和第二外绝缘层，所述第二内绝缘层和所述第二外绝缘层之间还设置有第二屏蔽层。
  8. 根据权利要求7所述的线缆连接结构，其特征在于，所述第一屏蔽层和所述第二屏蔽层分别与所述屏蔽层搭接，沿轴向方向，所述搭接的重叠区域的长度大于所述屏蔽层总长度的10％。
  9. 根据权利要求7所述的线缆连接结构，其特征在于，所述第一外绝缘层和所述第二外绝缘层分别与所述外热缩管搭接，沿轴向方向，所述搭接的重叠区域的长度大于所述外热缩管总长度的10％。
  10. 根据权利要求1所述的线缆连接结构，其特征在于，所述外热缩管为双壁热缩管。
PCT/CN2023/075353 2022-02-22 2023-02-10 一种线缆连接结构 WO2023160408A1 (zh)

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