WO2023174262A1 - 一种电能传输系统及一种汽车 - Google Patents
一种电能传输系统及一种汽车 Download PDFInfo
- Publication number
- WO2023174262A1 WO2023174262A1 PCT/CN2023/081326 CN2023081326W WO2023174262A1 WO 2023174262 A1 WO2023174262 A1 WO 2023174262A1 CN 2023081326 W CN2023081326 W CN 2023081326W WO 2023174262 A1 WO2023174262 A1 WO 2023174262A1
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- WIPO (PCT)
- Prior art keywords
- electrical connection
- shaped
- transmission system
- connection frame
- cavity
- Prior art date
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Classifications
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- 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
- H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
- B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
- B60L53/18—Cables specially adapted for charging electric vehicles
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- 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
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- 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
- H01B7/0233—Cables with a predominant gas dielectric
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R31/00—Coupling parts supported only by co-operation with counterpart
- H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
Definitions
- the present invention relates to the technical field of electric energy transmission, and more specifically, to an electric energy transmission system and an automobile.
- the layout environment in the car body is complex, requiring cables to be bent in multiple places. Changes in resistance at the bends of solid cables will cause the bends to heat up more than other locations, causing part of the insulation layer to soften or even melt, causing high-voltage discharge or short circuit. In addition, excessive heat will also affect the layout environment of the cable bend. When the melting point of the object close to the cable bend is low, the object will melt and the entire cable will be wrapped, making the heat dissipation effect worse. Eventually, the cable will overheat and burn, or even cause the vehicle to burn.
- the present invention provides a new technical solution.
- an electric energy transmission system including at least one electrical connection frame and connectors provided at both ends of the electrical connection frame.
- An insulating layer is provided on the outside of the electrical connection frame.
- the connecting frame has at least one bent portion, and at least part of the bent portion contains at least one cavity, and the cavity is located between the inner wall of the insulation layer and the outer periphery of the electrical connecting frame.
- the air pressure value in the cavity is greater than the air pressure value of the environment where the electrical connection skeleton is located.
- the cavity contains a barrier breakdown medium, and the dielectric breakdown strength of the barrier breakdown medium is greater than the dielectric breakdown strength of air.
- the barrier breakdown medium contains one or more of silicon compounds, halogen compounds, nitrogen compounds, and carbon compounds.
- the electrical connector includes a connection terminal, and both ends of the electrical connection frame are electrically connected to the connection terminal.
- connection terminal is made of copper or copper alloy.
- the electrical connection frame is made of aluminum or aluminum alloy, and the electrical connection frame and the connection terminal are electrically connected by welding or crimping.
- the electrical connection skeleton is a rigid body, and the tensile strength of the electrical connection skeleton is greater than 75 MPa.
- the cross-sectional shape of the electrical connection skeleton is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, H-shaped, One or more of K-shape, L-shape, P-shape, T-shape, U-shape, V-shape, W-shape, X-shape, Y-shape, Z-shape, semi-arc shape, arc shape, and wavy shape.
- edges are chamfered or rounded.
- the bending radius of the bending portion is greater than or equal to 1.19 times the maximum outer diameter of the electrical connection frame.
- the maximum radial height of the cavity is less than or equal to 3 times the thickness of the insulation layer.
- the radial height of the cavity gradually decreases from the middle to the periphery of the cavity.
- the maximum dimension of the cavity occupying the surface of the electrical connection skeleton is less than or equal to the maximum outer diameter of the electrical connection skeleton.
- the sum of the areas of the cavity on the surface of the curved portion accounts for 20%-80% of the surface area of the curved portion.
- the radial shape of the cavity is circular, elliptical, polygonal, fan-shaped, prismatic or fusiform.
- the present invention also provides an automobile, including the electric energy transmission system as described above.
- the sealed air in the cavity will expand when the bent part of the electrical connection skeleton is heated. However, due to the existence of the insulating layer, the pressure in the cavity will gradually increase. According to Paschen's law, the greater the air pressure, the greater the breakdown. The higher the voltage, the higher the voltage breakdown resistance of the bending part will be, and the safety of the power transmission system will be improved.
- Figure 1 is a schematic structural diagram of the connector assembly of the present invention
- Figures 2-4 are schematic structural diagrams of the bending portion of the electrical connection frame of the present invention.
- Figures 5, 8, and 9 are cross-sectional views of different cross-sectional areas of the electrical connection skeleton of the present invention.
- Figures 6-7 are schematic diagrams of the cavity structure of the present invention.
- Figure 10 is a schematic structural diagram of the bending part of the present invention.
- any specific values are to be construed as illustrative only and not as limiting. Accordingly, other examples of the exemplary embodiments may have different values.
- An electric energy transmission system includes at least one electrical connection frame 1, an insulation layer 2 sleeved on the outer wall of the electrical connection frame 1, and connections provided at both ends of the electrical connection frame 1 Device 3, the electrical connection frame 1 has at least one bent portion 4, and in at least part of the bent portion 4, at least one cavity 6 is provided between the inner wall of the insulating layer 2 and the outer periphery of the electrical connection frame 1.
- the cross-sectional area of the electrical connection frame 1 is carefully calculated based on the conduction current, and sufficient margin will be left, even if the current conduction of the electrical connection frame 1 is due to voltage instability, etc. The reasons are If the rated current exceeds the rated current, the electrical connection frame 1 will only cause heat, but will not cause the electrical connection frame 1 to fuse or burn.
- the insulating layer 2 covering the electrical connection skeleton 1 is made of plastic material, and its melting temperature is between 115°C and 120°C.
- the insulation layer 2 needs to be covered with tape, sponge, etc. The melting temperature of objects with low melting points will be below 100 degrees Celsius. Therefore, when the current is too large and the temperature rises beyond the standard, the outer insulation layer 2 or materials such as tape or sponge need to be protected from melting or Burning items.
- the sealed air in the cavity 6 will expand when the bent portion 4 of the electrical connection frame 1 heats up. However, due to the existence of the insulating layer 2, the pressure in the cavity 6 will gradually increase. According to Paschen's law, the air pressure increases as the air pressure increases. The larger the voltage, the higher the breakdown voltage. Therefore, the voltage breakdown resistance of the bending part 4 will be improved, and the safety of the power transmission system will be improved.
- the air pressure value in the cavity 6 is greater than the air pressure value of the environment where the electrical connection skeleton 1 is located. Only when the atmospheric pressure value of the cavity 6 is greater than the external air pressure value can the cavity 6 be supported from the inside and prevent the collapse of the cavity 6 . At the same time, according to Paschen's law, the greater the air pressure, the higher the breakdown voltage. Therefore, the voltage breakdown resistance of the bent part 4 will be improved, and the safety of the electric energy transmission system will be improved.
- the cavity 6 contains a barrier breakdown medium, and the dielectric breakdown strength of the barrier breakdown medium is greater than the dielectric breakdown strength of air.
- the barrier breakdown medium has higher resistance to breakdown.
- the voltage of the electrical connection frame 1 is high, it is easy to generate an electric field when it is close to external conductive devices. If the insulation layer 2 has poor resistance to breakdown, the electric field will breakdown the insulation layer. This may cause an instant short circuit, and in serious cases may cause damage to the vehicle. Therefore, adding a barrier breakdown medium in the cavity 6 can improve the anti-breakdown capability of the insulating layer 2 and improve the safety of the power transmission system.
- the barrier breakdown medium contains one or more of silicon compounds, halogen compounds, nitrogen compounds, and carbon compounds. These compounds have good thermal conductivity and can fully assist in heat dissipation; their thermal expansion coefficient is small, which can prevent the cavity 6 from bursting from the inside; at the same time, they have good electrical insulation properties, small dielectric coefficient, and high breakdown voltage resistance, which can more effectively prevent shock. wear.
- the inventor selected the same size of the electrical connection skeleton 1, the same size of the bending part 4, the same size
- the cavity 6 has the same pressure value, and the cavity 6 does not contain a barrier breakdown medium, and the cavity 6 contains There are different barrier breakdown media, conduct breakdown voltage test respectively, observe the voltage value during breakdown, and record it in Table 1. In this embodiment, a breakdown voltage value greater than 2.1KV is considered a qualified value.
- Test method for the breakdown voltage of the bent part 4 pass a stable current through the power transmission system, and set electrodes on the electrical connection frame 1 and the insulating layer 2 of the bent part 4 respectively, and pass DC high voltage to the two electrodes. When both When an electrode breaks down, record the voltage value at that time. In this embodiment, a breakdown voltage value greater than 2.1KV is considered a qualified value.
- the breakdown voltage value of the bending part 4 is greater than 2.1KV, which is close to the qualified critical value, that is, it does not exceed the qualified value too much. At this time There is also a risk to the breakdown resistance of the bent portion 4 .
- the barrier breakdown medium inside the cavity 6 contains silicon compounds, halogen compounds, nitrogen compounds, and carbon compounds
- the breakdown voltage value of the bent portion 4 exceeds the qualified value by a large amount, and the breakdown resistance performance is significantly better than that inside the cavity 6 .
- the inventors set the barrier breakdown medium to contain one or more of silicon compounds, halogen compounds, nitrogen compounds, and carbon compounds.
- the electrical connector 3 includes connection terminals 5 , and both ends of the electrical connection frame 1 are electrically connected to the connection terminals 5 .
- the connecting terminal 5 is used to be plugged into the terminal of the opposite plug end so as to conduct current and realize power transmission.
- connection terminal 5 is made of copper or copper alloy.
- connection terminals 5 made of copper or copper alloy for plug-in and pull-out connections.
- the connection terminal 5 It can be widely used in various electrical transmission scenarios.
- the electrical connection frame 1 is made of aluminum or aluminum alloy, and the electrical connection frame 1 and the connection terminal 5 are electrically connected by welding or crimping.
- the specific material of the electrical connection skeleton 1 can be aluminum or copper-aluminum alloy, aluminum-magnesium alloy, aluminum-lithium alloy, aluminum-zinc alloy, etc.
- the material of the electrical connection terminal 5 is copper or copper alloy.
- the metal inertness of copper is greater than that of aluminum.
- the electrode potential difference between copper and aluminum is 1.9997V.
- the specific welding method is one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction welding.
- Resistance welding refers to a method that uses strong current to pass through the contact point between the electrode and the workpiece, and generates heat due to the contact resistance to achieve welding.
- Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
- Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
- the arc welding method refers to using the arc as a heat source and utilizing the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of joining metals.
- the main methods include electrode arc welding, submerged arc welding, and gas shielding. Welding etc.
- Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
- Electron beam welding 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 melts to achieve welding.
- Pressure welding is a method of applying pressure to the weldment to bring the joint surfaces into close contact to produce a certain degree of plastic deformation to complete the welding.
- Diffusion welding refers to a solid-state welding method that pressurizes the workpiece at high temperatures without causing visible deformation or relative movement.
- the specific welding method selects an appropriate connection method or combination of connection methods based on the actual status of the electrical connection frame 1 and the connection terminal 5 to achieve an effective electrical connection.
- Crimping is a production process in which the electrical connection frame 1 and the connection terminal 5 are assembled, and then the two are stamped into one body using a crimping machine.
- the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
- the electrical connection skeleton 1 is a rigid body, and the tensile strength of the electrical connection skeleton 1 is greater than 75 MPa.
- the electrical connection frame 1 uses a rigid conductor, which will not rub against the vehicle shell when the entire vehicle vibrates, thus ensuring the integrity of the electrical connection frame 1 .
- a rigid body is an object whose shape and size remain unchanged during motion and after being subjected to force, and the relative positions of internal points remain unchanged.
- absolutely rigid bodies do not actually exist. They are just an ideal model, because any object will deform more or less after being subjected to force. If the degree of deformation is extremely small relative to the geometric size of the object itself, it is difficult to study The deformation of the object during motion is negligible. Therefore, during use, the amount of deformation produced by the electrical connection skeleton 1 made of rigid body material is negligible. The greater the tensile strength of the rigid body, the smaller the deformation amount.
- the inventor selected the same size specifications and used different resistance
- the tensile strength of the electrical connection skeleton 1 sample was tested on the tensile force value when the electrical connection skeleton 1 was broken, the torque during bending and the abnormal sound during vibration.
- Test method for the tensile force value of the electrical connection frame 1 Use a universal tensile testing machine, fix both ends of the electrical connecting frame 1 on the tensile fixture of the universal tensile testing machine, and stretch at a speed of 50mm/min. Record the tensile force value at the final break. In this embodiment, a tensile force value greater than 1600N is considered a qualified value.
- Torque test method of electrical connection skeleton 1 Use a torque tester to bend the electrical connection skeleton 1 at 90° with the same radius and the same speed, and test the torque value of the deformation of the electrical connection skeleton 1 during the bending process.
- a torque value less than 60 N ⁇ m is a preferred value.
- the test method is to select electrical connection skeleton 1 samples of the same size and specifications and different tensile strengths, assemble the connectors 2 of the same specifications together, and fix them on the vibration test bench. During the vibration test, observe whether there is any abnormal sound in the electrical connection frame 1.
- the tensile strength of the electrical connection skeleton 1 is less than 75MPa
- the tensile force value of the electrical connection skeleton 1 when it is broken is less than 1600N.
- the strength of the electrical connection skeleton 1 itself is not high, and it is subject to smaller It is easily broken by external force, causing the function of the electrical connection skeleton 1 to fail, thereby failing to achieve the purpose of transmitting electric energy.
- the inventor prefers that the tensile strength of the electrical connection skeleton 1 is greater than 75 MPa.
- the cross-sectional shape of the electrical connection skeleton 1 is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, P-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, semi-arc shape, arc shape, wavy shape one or more.
- the cross-sectional shape of the electrical connection skeleton 1 is circular, rectangular and hexagonal, which can better route wiring according to the outline of the electric vehicle body, reducing Wiring supplies.
- edges are chamfered or rounded.
- the outer periphery of the electrical connection skeleton 1 is covered with an insulating layer 2 to prevent the edges from being damaged by friction with the insulating layer 2, so the edges are chamfered or rounded.
- the bending radius of the bending portion 4 is greater than or equal to 1.19 times the maximum outer diameter of the electrical connection frame 1 .
- the electrical connection skeleton 1 Compared with multi-core aluminum wires, the electrical connection skeleton 1 has very good rigidity and is less likely to break during the bending process.
- the electrical connection skeleton 1 is used to connect the first connector and the second connector, so that the first connector can be connected to the first connector.
- the current input by the connector enters the vehicle battery through the second connector.
- the electrical connection frame 1 is arranged along the car shell. If it is too close to the car shell, the electrical connection frame 1 will interfere with the car shell and make abnormal noises when the car is moving. After testing by the inventor, when the distance between the electrical connection frame 1 and the car shell is the minimum When the distance is greater than or equal to 5mm, it can effectively prevent the occurrence of abnormal noise.
- a big advantage of the electrical connection skeleton 1 as a conductor is that it is easy to bend. However, if the bending radius of the bend is too small, the electrical connection skeleton 1 inside the bend will be affected. to greater compression, and the bent outer electrical connection skeleton 1 is subject to greater stretching, which will cause more wrinkles and fractures inside the electrical connection skeleton 1, which will increase the resistance of the electrical connection skeleton 1 and affect the electrical connection. According to the conductivity of the skeleton 1, the inventor has tested that when the bending radius of the electrical connection skeleton 1 is greater than or equal to 1.19 times the maximum outer diameter of the electrical connection skeleton 1, no wrinkles or breaks will occur inside the electrical connection skeleton 1.
- the inventor selected the same cross-sectional shape and the same size of the electrical connection frame 1, and made them into samples with different bending radii, and then conducted the same conduction. Current, respectively test the temperature rise of the bending part 4.
- Test method for the temperature rise of the bending part 4 Enclose the bending part 4 in a closed space of the same size, and set up multiple temperature sensors in the closed space. When the power transmission system is not powered, measure the temperature value in the closed space and obtain the result. average value, and then pass a stable current through the power transmission system. After the temperature in the enclosed space stabilizes, measure the temperature value in the enclosed space and take the average value. Subtract the two average temperature values, which is the temperature of the bending part 4. appreciation. In this embodiment, a temperature rise value less than 50K is considered a qualified value.
- Table 3 The influence of the ratio of the bending radius of the bending part 4 to the maximum outer diameter of the electrical connection frame 1 on the temperature rise of the bending part 4
- the temperature rise value of the bending part 4 is greater than 50K, which is considered unqualified.
- the ratio of the bending radius of the bending portion 4 to the maximum outer diameter of the electrical connection frame 1 is greater than 1.19 times, the temperature rise value of the bending portion 4 gradually decreases, and the trend is obvious. Therefore, the inventor sets the bending radius of the bending portion 4 to be greater than or equal to 1.19 times the maximum outer diameter of the electrical connection frame 1 .
- the distance between two adjacent bending parts 4 refers to the length of the straight-line electrical connection skeleton 1 between the two bending parts 4.
- the straight-line electrical connection skeleton 1 is calculated according to The design requires that the electrical connection frame 1 of corresponding size be bent to a certain radius and angle to adapt to the installation environment, so that the electrical connection frame 1 can be more appropriately installed inside the vehicle body.
- part of the electrical connection skeleton 1 needs to be fixed so that the straight electrical connection skeleton 1 can be bent.
- the length of the fixed electrical connection skeleton 1 must not be too small. It must be greater than 2.6 times the maximum outer diameter of the electrical connection frame 1 to effectively fix the electrical connection frame 1 and not cause the electrical connection frame 1 to move or deform when it is bent, ensuring that the bending part 4 can be formed.
- the inventor selected electrical connection frame 1 with the same size, respectively. Bending is performed at different distances from each other, and 50 bendings are performed respectively. The number of samples with good bending is recorded, and the success rate of bending is calculated. In this embodiment, the bending success rate is greater than 95% as qualified.
- the maximum radial height of the cavity 6 is less than or equal to three times the thickness of the insulating layer 2 .
- the radial height of the cavity 6 is too high. During the wiring process, a narrow space may be encountered. The radial height of the cavity 6 is too high, which will affect the wiring. At the same time, the protrusions of the insulating layer 2 of the cavity 6 will also interfere with the wiring. The friction of the vehicle shell or other parts causes the insulating layer 2 to break. The inventor limits the maximum radial height of the cavity 6 to be less than or equal to 3 times the thickness of the insulating layer 2 .
- the inventor selected the electrical connection skeleton 1 of the same size, the insulating layer 2 of the same thickness, and the different thicknesses of the cavity 6 For the specimens with the maximum radial height, install the specimens on the vibration test stand respectively, and simulate the installation of other electrical parts at the attachment of the electrical connection frame 1, and then conduct a vibration test to observe the wear of the insulation layer 2 after the vibration test. In this embodiment, the insulating layer 2 is deemed to be unqualified if it is worn.
- the insulating layer 2 of the electrical connection skeleton 1 has no wear and is in a qualified state.
- the ratio of the maximum radial height of the cavity 6 to the thickness of the insulating layer 2 is greater than 3 times, the insulating layer 2 of the electrical connection skeleton 1 begins to wear and becomes unqualified. Therefore, the inventor sets the maximum radial height of the cavity 6 to be less than or equal to three times the thickness of the insulation layer 2 .
- the radial height of the cavity 6 gradually decreases from the middle to the periphery of the cavity 6 .
- the radial height of the cavity 6 gradually decreases from the middle toward the periphery.
- the maximum dimension of the cavity 6 occupying the surface of the electrical connection frame 1 is less than or equal to the maximum outer diameter of the electrical connection frame 1 .
- the cavity 6 is distributed on the surface of the electrical connection skeleton 1 and is a cavity formed between the electrical connection skeleton 1 and the insulating layer 2.
- the cavity 6 is on the surface of the electrical connection skeleton 1
- the insulating layer 2 will sink under the influence of external force or its own gravity, thereby approaching or contacting the surface of the electrical connection skeleton 1, causing the larger-sized cavity 6 to become several smaller-sized cavities 6. Therefore, when the size of the cavity 6 on the surface of the electrical connection frame 1 is large, it has no practical practicability. Instead, the volume of the cavity 6 cannot be controlled, resulting in the heat of the electrical connection frame 1 being unable to be controlled within the design range.
- the inventor set The maximum size of the cavity 6 on the surface of the electrical connection frame 1 is less than or equal to the maximum outer diameter of the electrical connection frame 1 .
- the total area of the cavity 6 on the surface of the curved portion 4 accounts for 20%-80% of the surface area of the curved portion 4 .
- the sum of the areas of the cavities 6 on the surface of the curved part 4 refers to the sum of the areas of multiple cavities 6 on the surface of the curved part 4 .
- the electrical connection frame 1 and the insulating layer 2 are of the same size, and the curved portion 4 of the same size is prepared. Cavities 6 of the same size are provided on the curved portion 4, but the number is inconsistent. The area of the cavity 6 on the surface of the curved portion 4 is and are inconsistent, test the temperature rise and breakdown voltage of the bent part 4 respectively, and record the results in Table 2.
- Test method for the temperature rise of the bending part 4 Enclose the bending part 4 in a closed space of the same size, and set up multiple temperature sensors in the closed space. When the power transmission system is not powered, measure the temperature value in the closed space and obtain the result. flat average value, and then pass a stable current through the electric energy transmission system. After the temperature in the closed space stabilizes, measure the temperature value in the closed space and take the average value. Subtract the two average temperature values, which is the temperature rise value of the bending part 4. . In this embodiment, a temperature rise value less than 50K is considered a qualified value.
- Test method for the breakdown voltage of the bent part 4 pass a stable current through the power transmission system, and set electrodes on the electrical connection frame 1 and the insulating layer 2 of the bent part 4 respectively, and pass DC high voltage to the two electrodes. When both When an electrode breaks down, record the voltage value at that time. In this embodiment, a breakdown voltage value greater than 2.1KV is considered a qualified value.
- the radial shape of the cavity 6 is circular, elliptical, polygonal, fan-shaped, prismatic or fusiform. Users can choose different radial shapes according to different environments and usage requirements.
- the connector 3 is a charging stand. As shown in Figure 1, one end of the electrical connection frame 1 is connected to the connection terminal 5 and then connected to the charging stand.
- the connection terminal 5 is arranged in the connector 3 and the other end can be connected to the vehicle battery to form a complete charging system.
- An automobile includes the above electric energy transmission system.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Electric Propulsion And Braking For Vehicles (AREA)
Abstract
本发明公开了一种电能传输系统及一种汽车,包括至少一根电连接骨架、套接在所述电连接骨架外壁的绝缘层和设置在所述电连接骨架两端的连接器,所述电连接骨架具有至少一个弯曲部,在所述弯曲部至少部分中,所述绝缘层内壁到所述电连接骨架外周之间设置有至少一个腔体。此结构的设置能保证电能传输系统的安全性得到很大提高。
Description
本申请要求2022年3月14日递交的申请号为CN202210248435.2、发明名称为“一种电能传输系统及一种汽车”的中国专利申请的优先权,其全部内容通过引用结合在本申请中。
本发明涉及电能传输技术领域,更具体地,涉及一种电能传输系统及一种汽车。
随着汽车上的电器越来越多,大功率线缆也越来越多的被使用在汽车上,目前的大功率线缆多数采用多芯的柔性线缆,多芯的线缆虽然较柔软,能够方便加工和布线,都是由于线径过粗,重量较大,在汽车行驶过程中,线缆会频繁的摩擦车壳,导致线缆的绝缘层破损,造成高压放电或短路,轻则损坏车辆,重则会造成严重的交通事故。因此,实心的线缆成为替代柔性线缆的主要选择之一。
但是,车身内的布局环境复杂,需要线缆由多处弯曲成型,实心的线缆弯曲处的电阻发生变化,会造成弯曲处发热大于其它位置,造成部分绝缘层软化甚至熔化,造成高压放电或短路。另外,过高的热量也会对线缆弯曲处的布置环境造成影响,当紧贴线缆弯曲处的物体熔点较低时,会造成此物体熔化导致线缆整体被包裹,散热效果更差,最终导致线缆过热烧毁,甚至引发车辆燃烧。
因此,现有技术中亟需一种新的方案来解决上述问题。
发明内容
为了解决上述问题,本发明提供了一种新技术方案。
根据本发明的第一方面,提供了一种电能传输系统,包括至少一根电连接骨架和设置在所述电连接骨架两端的连接器,所述电连接骨架外侧设置有绝缘层,所述电连接骨架具有至少一个弯曲部,至少部分的所述弯曲部含有至少一个腔体,所述腔体位于所述绝缘层内壁到所述电连接骨架外周之间。
所述腔体内气压值大于所述电连接骨架所处环境的气压值。
所述腔体内包含阻挡击穿介质,所述阻挡击穿介质的介电击穿强度大于空气的介电击穿强度。
所述阻挡击穿介质含有硅化合物、卤化合物、氮化合物、碳化合物的一种或几种。
所述电连接器包含连接端子,所述电连接骨架两端与所述连接端子电连接。
所述连接端子的材质为铜或铜合金。
所述电连接骨架材质为铝或铝合金,所述电连接骨架与所述连接端子通过焊接或压接的方式电连接。
所述电连接骨架为刚性体,所述电连接骨架的抗拉强度大于75MPa。
所述电连接骨架的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、P形、T形、U形、V形、W形、X形、Y形、Z形、半弧形、弧形、波浪形中的一种或多种。
所述电连接骨架的横截面有棱边时,所述棱边倒角或倒圆。
所述弯曲部的弯曲半径大于等于所述电连接骨架最大外径的1.19倍。
所述弯曲部为至少两个,相邻两个所述弯曲部的距离大于等于所述电连接骨架最大外径的2.6倍。
所述腔体的径向最大高度,小于等于所述绝缘层厚度的3倍。
所述腔体的径向高度,从所述腔体的中间向四周逐渐减小。
所述腔体的占所述电连接骨架表面的最大尺寸,小于等于所述电连接骨架最大外径。
所述腔体在所述弯曲部表面上的面积之和,占所述弯曲部表面积的20%-80%。
所述腔体的径向形状为圆形、椭圆形、多边形、扇形、棱形或梭形。
本发明还提供了一种汽车,包括如上所述的电能传输系统。
本发明的技术效果如下:
1、电连接骨架的弯曲部与绝缘层内壁之间存在腔体,腔体内存有空气,密闭空气的导热效果较差,因此当电连接骨架的弯曲部发热量较大时,不会影响到腔体外的绝缘层,从而保护弯曲部的绝缘层不会软化或熔化。
2、由于腔体内存有密闭空气有隔热作用,电连接骨架的弯曲部的热量无法传递到绝缘层之外,使包覆绝缘层的胶布、海绵等熔点低的物体不会受热熔化,降低了事故的发生概率。
3、腔体内存有的密闭空气在电连接骨架的弯曲部发热时会膨胀,但由于绝缘层的存在,会使腔体内的压力逐渐增大,根据帕邢定律,空气压力越大,击穿电压越高,因此会使弯曲部的耐电压击穿能力提升,电能传输系统的安全性得到提高。
通过以下参照附图对本发明的示例性实施例的详细描述,本发明的其它特征及其优点将会变得清楚。
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发明的实施例,并且连同其说明一起用于解释本发明的原理。
图1为本发明连接器总成的结构示意图;
图2-图4为本发明电连接骨架弯曲部的结构示意图;
图5、图8、图9为本发明电连接骨架不同横截面积的剖面图;
图6-图7为本发明腔体结构示意图;
图10为本发明弯曲部结构示意图。
图中标示如下:
1、电连接骨架;2、绝缘层;3、连接器;4、弯曲部;5、连接端子;6、腔体。
1、电连接骨架;2、绝缘层;3、连接器;4、弯曲部;5、连接端子;6、腔体。
现在将参照附图来详细描述本发明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发明的范围。
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,决不作为对本发明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。
一种电能传输系统,如图1-图10所示,包括至少一根电连接骨架1、套接在所述电连接骨架1外壁的绝缘层2和设置在所述电连接骨架1两端的连接器3,所述电连接骨架1具有至少一个弯曲部4,在所述弯曲部4至少部分中,所述绝缘层2内壁到所述电连接骨架1外周之间设置有至少一个腔体6。
在电能传输系统的设计过程中,电连接骨架1的截面积是根据导通电流进行周密的计算的,并且会留有充分的余量,即使电连接骨架1导通的电流由于电压不稳等原因有
超过额定电流的情况,电连接骨架1也只会导致发热,不会使电连接骨架1熔断或烧毁。但是电连接骨架1外包覆的绝缘层2为塑料材质,其熔融温度在115℃到120℃之间,另外电连接骨架1在安装的时候,绝缘层2外还需要包覆胶布、海绵等熔点低的物体,其熔融温度会在100摄氏度以下,因此,电连接骨架1在电流过大,温度升温超标时,其外周的绝缘层2或胶布或海绵等材料,才是需要保护不能熔化或者燃烧的物品。
如图6-图7所示,电连接骨架1的弯曲部4与绝缘层2内壁之间存在腔体6,腔体6内存有空气,密闭空气的导热效果较差,因此当电连接骨架1的弯曲部4发热量较大时,不会影响到腔体6外的绝缘层2,从而保护弯曲部4的绝缘层2不会软化或熔化。
由于腔体6内存有密闭空气有隔热作用,电连接骨架1的弯曲部4的热量无法传递到绝缘层2之外,使包覆绝缘层2的胶布、海绵等熔点低的物体不会受热熔化,降低了事故的发生概率。
腔体6内存有的密闭空气在电连接骨架1的弯曲部4发热时会膨胀,但由于绝缘层2的存在,会使腔体6内的压力逐渐增大,根据帕邢定律,空气压力越大,击穿电压越高,因此会使弯曲部4的耐电压击穿能力提升,电能传输系统的安全性得到提高。
在一些实施例中,所述腔体6内气压值大于所述电连接骨架1所处环境的气压值。只有腔体6的大气压值大于外部的气压值,才能从内支撑腔体6,防止腔体6的塌陷。同时,根据帕邢定律,空气压力越大,击穿电压越高,因此会使弯曲部4的耐电压击穿能力提升,电能传输系统的安全性得到提高。
在一些实施例中,所述腔体6内包含阻挡击穿介质,所述阻挡击穿介质的介电击穿强度大于空气的介电击穿强度。阻挡击穿介质具有更高的抗击穿能力,当电连接骨架1的电压较高时,与外界导电装置接近后,容易产生电场,若绝缘层2抗击穿能力差,电场会将绝缘层击穿导致瞬间短路,严重时会造成车辆损坏,因此,在腔体6内添加阻挡击穿介质能够提高绝缘层2部分的抗击穿能力,更能够提高电能传输系统的安全性。
在一些实施例中,所述阻挡击穿介质含有硅化合物、卤化合物、氮化合物、碳化合物的一种或几种。这几种化合物导热性能好,能够充分的辅助散热;热膨胀系数小,能够避免从内部胀破腔体6;同时电绝缘性能好,介电系数小,抗击穿电压高,能够更有效的防止击穿。
为了验证腔体6内不含有阻挡击穿介质和含有不同阻挡击穿介质对弯曲部4抗击穿效果的影响,发明人选用了相同尺寸的电连接骨架1,相同尺寸的弯曲部4,相同尺寸的腔体6,腔体6内为相同的压力值,分别设置腔体6内部不含有阻挡击穿介质,以及含
有不同的阻挡击穿介质,分别做耐击穿电压的测试,观察击穿时的电压值,并记录在表1中。在本实施例中,耐击穿电压值大于2.1KV为合格值。
弯曲部4的耐击穿电压的测试方法:对电能传输系统进行通稳定电流,并在弯曲部4的电连接骨架1和绝缘层2分别设置电极,并在两个电极通直流高压,当两个电极发生击穿时,记录当时的电压值。在本实施例中,耐击穿电压值大于2.1KV为合格值。
表1,腔体内不含有阻挡击穿介质和含有不同阻挡击穿介质,对弯曲部4的温升和击穿电压的影响,
从上表1可以看出,当腔体6内部不含有阻挡击穿介质时,弯曲部4的耐击穿电压值大于2.1KV,为贴近合格临界值,即没有超出合格值太多,此时弯曲部4的耐击穿性能还存在风险。当腔体6内部的阻挡击穿介质含有硅化合物、卤化合物、氮化合物、碳化合物时,弯曲部4的耐击穿电压值超出合格值很多,耐击穿性能显著优于腔体6内部不含有阻挡击穿介质时。因此,发明人设定阻挡击穿介质含有硅化合物、卤化合物、氮化合物、碳化合物的一种或几种。
如图1所示,所述电连接器3包含连接端子5,所述电连接骨架1两端与所述连接端子5电连接。连接端子5用于和对插端的端子插接,从而时间电流的导通,以实现电能传输。
在具体的实施方式中,所述连接端子5的材质为铜或铜合金。
铜或铜合金导电率高,并且耐摩擦,而且目前大多数的用电装置的接电部分材质都是铜,因此需要使用材质为铜或铜合金的连接端子5进行插拔连接,连接端子5可以广泛应用于各种电传输场景。
在具体的实施方式中,所述电连接骨架1材质为铝或铝合金,所述电连接骨架1与所述连接端子5通过焊接或压接的方式电连接。
电连接骨架1的材质具体的可以采用铝或铜铝合金、铝镁合金、铝锂合金、铝锌合金等。
电连接端子5的材质为铜或铜合金,铜的金属惰性要大于铝,铜与铝之间的电极电位差为1.9997V,这两种金属连接通电后会发生电化学反应,导致铝线逐渐被氧化,降
低铝线的机械强度和导电性,采用焊接的方式可以实现异种材料的连接,由于接触位置相融,导电效果更好。
具体的焊接方式为电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接的一种或几种。
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。
具体焊接方式根据电连接骨架1和连接端子5的实际状态,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。
压接方式,压接是将电连接骨架1和连接端子5装配后,使用压接机,将两者冲压为一体的生产工艺。压接的优点是量产性,通过采用自动压接机能够迅速大量的制造稳定品质的产品。
在具体的实施方式中,所述电连接骨架1为刚性体,所述电连接骨架1的抗拉强度大于75MPa。
电连接骨架1采用刚性导体,在车辆整体震动时不会与车壳进行摩擦,能够保证电连接骨架1的完整性。
刚性体是指在运动中和受力作用后,形状和大小不变,而且内部各点的相对位置不变的物体。绝对刚性体实际上是不存在的,只是一种理想模型,因为任何物体在受力作用后,都或多或少地变形,如果变形的程度相对于物体本身几何尺寸来说极为微小,在研究物体运动时变形就可以忽略不计。所以,由刚性体材料制成的电连接骨架1在使用过程中,产生的形变量微乎其微,可忽略不计,刚性体的抗拉强度越大,其变形量越小。
为了验证电连接骨架1的抗拉强度,对电连接骨架1拉断时的拉力值,折弯的扭矩以及振动过程中是否发生异响的影响,发明人选用了相同尺寸规格的,使用不同抗拉强度的电连接骨架1样件,对电连接骨架1拉断时的拉力值,折弯时的扭矩和振动过程中的异响进行测试。
电连接骨架1的拉力值的测试方法:使用万能拉力测试机,将电连接骨架1,两端分别固定在万能拉力测试机的拉伸治具上,并以50mm/min的速度进行拉伸,记录最终拉断时的拉力值,在本实施例中,拉力值大于1600N为合格值。
电连接骨架1的扭矩测试方法:使用扭矩测试仪,将电连接骨架1以相同的半径,相同的速度弯折90°的时候,测试弯折过程中电连接骨架1变形的扭矩值,在本实施例中,扭矩值小于60N·m为优选值。
电连接骨架1是否会出现异响,试验方法为选择相同尺寸规格的,使用不同抗拉强度的电连接骨架1样件,相同规格的连接器2组装在一起,固定在振动试验台上,在振动试验过程中,观察电连接骨架1是否会出现异响。
表2:不同的抗拉强度对电连接骨架1的扭矩值和异响的影响
从上表2中可以看出,当电连接骨架1抗拉强度为小于75MPa时,电连接骨架1拉断时的拉力值小于1600N,此时电连接骨架1本身的强度不高,受到较小外力时容易拉断,造成电连接骨架1功能失效,从而无法起到电能传输的目的。
另一方面,由于电连接骨架1的抗拉强度值越大,电连接骨架1越不易发生形变,所以振动试验过程中,电连接骨架1越不容易相对两端连接的连接器3振动而产生异响,相反,电连接骨架1的抗拉强度值越小,电连接骨架1越容易发生形变,所以振动试验过程中,电连接骨架1越容易相对两端连接的连接器3振动而产生异响。从上表1中可以看出,当电连接骨架1抗拉强度为小于等于75MPa时,电连接骨架1在振动试验过程中会产生异响。所以发明人优选电连接骨架1的抗拉强度大于75MPa。
同时,在表1中也能看出,当电连接骨架1抗拉强度为大于480MPa时,电连接骨架1折弯90°时的扭矩值大于60N·m,此时,电连接骨架1不容置折弯,因此,发明人进一步优选电连接骨架1抗拉强度为大于75MPa且小于等于480MPa。
在一具体的实施方式中,所述电连接骨架1的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、P形、U形、V形、W形、X形、Y形、Z形、半弧形、弧形、波浪形中的一种或多种。更进一步的,具体的如图5,图8和图9所示,电连接骨架1的横截面形状呈圆形、矩形和六边形,能够更好的根据电动车辆车身的轮廓进行布线,减少布线耗材。
所述电连接骨架1的横截面有棱边时,所述棱边倒角或倒圆。
电连接骨架1的外周包覆绝缘层2,防止棱边与绝缘层2摩擦损坏,所以把棱边设置成倒角或倒圆。
所述弯曲部4的弯曲半径大于等于所述电连接骨架1最大外径的1.19倍。
电连接骨架1相较于多芯铝线,具有很好的刚性,不易在折弯的过程中出现断裂,本发明用电连接骨架1连接第一连接器和第二连接器,使从第一连接器输入的电流经第二连接器进入车载电池中。电连接骨架1沿车壳布置,如果距离车壳太近,则在汽车运动中,电连接骨架1会与车壳干涉发出异响,经发明人测试,当电连接骨架1距离车壳的最小距离大于等于5mm时,能够有效杜绝异响的出现。电连接骨架1作为导体的很大一个优势在于它容易折弯,但是如果折弯的弯曲半径太小,弯曲内部的电连接骨架1受
到较大的压缩,而弯曲外部的电连接骨架1受到较大的拉伸,会使电连接骨架1内部出现较多的褶皱和断裂,这样就会增加电连接骨架1的电阻,影响电连接骨架1的导电率,因此经发明人测试,电连接骨架1的弯曲半径,大于等于所述电连接骨架1最大外径的1.19倍时,电连接骨架1内部不会出现褶皱和断裂。
发明人为了验证弯曲部4的弯曲半径对电连接骨架1温升的影响,选用了相同截面形状,相同尺寸的电连接骨架1,分别制作成不同弯曲半径的样件,然后进行导通相同的电流,分别测试弯曲部4的温升。
弯曲部4的温升的测试方法:将弯曲部4封闭在相同大小的密闭空间中,并在密闭空间设置多个温度传感器,在电能传输系统未通电时,测量密闭空间内的温度值并取平均值,然后对电能传输系统进行通稳定电流,等到密闭空间内的温度稳定后,测量密闭空间内的温度值并取平均值,将两个温度平均值相减,即是弯曲部4的温升值。在本实施例中,温升值小于50K为合格值。
表3,弯曲部4的弯曲半径与电连接骨架1最大外径的比例,对弯曲部4的温升的影响
从上表3可以看出,当弯曲部4的弯曲半径与电连接骨架1最大外径的比例小于1.19倍时,弯曲部4的温升值大于50K,为不合格。当弯曲部4的弯曲半径与电连接骨架1最大外径的比例大于1.19倍时,弯曲部4的温升值逐渐减小,趋势明显。因此,发明人设定所述弯曲部4的弯曲半径大于等于电连接骨架1最大外径的1.19倍。
在具体的实施方式中,所述弯曲部4为至少两个,相邻两个所述弯曲部4的距离大于等于所述电连接骨架1最大外径的2.6倍。
如图10所示,相邻两个弯曲部4的距离,是指两个弯曲部4之间的直线段的电连接骨架1的长度,在实际操作中,是将直线的电连接骨架1按照设计要求,将相应尺寸的电连接骨架1弯曲到一定的半径和角度,以适配安装环境,使电连接骨架1能够更合适的安装在车身内部。在将电连接骨架1弯曲的过程中,需要将部分电连接骨架1进行固定,才能将直线的电连接骨架1进行弯曲,固定的电连接骨架1部分长度不能太小,必
须大于电连接骨架1最大外径的2.6倍,才能有效的将电连接骨架1固定住,不会在电连接骨架1弯曲时导致电连接骨架1移动或变形,保证弯曲部4能够成型。
发明人为了验证相邻两个弯曲部4的距离与电连接骨架1最大外径的倍数,与直线的电连接骨架1进行弯曲的成功率的影响,选用尺寸相同的电连接骨架1,分别在相邻不同的距离进行弯曲,分别进行50次弯曲,记录弯曲良好的样件数量,并计算弯曲的成功率。在本实施例中,弯曲的成功率大于95%为合格。
表4,相邻两个弯曲部4的距离与电连接骨架1最大外径的倍数,与直线的电连接骨架1进行弯曲的成功率的影响
从上表4可以看出,当相邻两个弯曲部4的距离与电连接骨架1最大外径的倍数小于2.6倍时,直线的电连接骨架1进行弯曲的成功率小于95%,为不合格。当相邻两个弯曲部4的距离与电连接骨架1最大外径的倍数大于2.6倍时,直线的电连接骨架1进行弯曲的成功率逐渐上升,趋势明显,因此,发明人设定相邻两个所述弯曲部4的距离大于等于所述电连接骨架1最大外径的2.6倍。
在具体的实施方式中,所述腔体6的径向最大高度,小于等于所述绝缘层2厚度的3倍。
所述腔体6的径向高度太高,在布线过程中,可能遇到狭窄空间,腔体6的径向高度过高会影响布线,同时腔体6部分绝缘层2的凸起也会与车壳或其他部件摩擦导致绝缘层2破裂,所述发明人将腔体6的径向最大高度限定为小于等于绝缘层2厚度的3倍。
发明人为了验证腔体6的径向最大高度与绝缘层2厚度的比例,对绝缘层2磨损的影响,选用尺寸相同的电连接骨架1,相同厚度的绝缘层2,不同的腔体6的径向最大高度的样件,分别将样件安装在振动试验台上,并在电连接骨架1附件模拟安装其他电器零件,然后进行振动试验,观察振动试验后,绝缘层2磨损的情况。在本实施例中,绝缘层2出现磨损为不合格。
表5,腔体6的径向最大高度与绝缘层2厚度的比例,对绝缘层2磨损的影响
从上表5可以看出,当腔体6的径向最大高度与绝缘层2厚度的比例小于等于3倍时,电连接骨架1的绝缘层2没有出现磨损,为合格状态。当腔体6的径向最大高度与绝缘层2厚度的比例大于3倍时,电连接骨架1的绝缘层2开始出现磨损,为不合格状态。因此,发明人设定腔体6的径向最大高度,小于等于绝缘层2厚度的3倍。
在具体的实施方式中,所述腔体6的径向高度,从所述腔体6的中间向四周逐渐减小。
如图2-图4所示,腔体6的径向高度中间向四周逐渐减小。
在具体的实施方式中,所述腔体6的占所述电连接骨架1表面的最大尺寸,小于等于所述电连接骨架1最大外径。
如图2-图4所示,腔体6分布在电连接骨架1的表面上,是电连接骨架1和绝缘层2之间形成的腔体,当腔体6在电连接骨架1的表面上的尺寸较大时,绝缘层2会在外力或自身重力的影响下陷,从而接近或接触电连接骨架1的表面,使得较大尺寸的腔体6变成几个较小尺寸的腔体6,因此,腔体6在电连接骨架1的表面上的尺寸较大时没有实际的实用性,反而使腔体6的体积无法控制,导致电连接骨架1的热量无法控制在设计范围内。经过发明人多次实验后,发现当腔体6在电连接骨架1的表面上的尺寸小于等于电连接骨架1最大外径时,腔体6不会出现下陷的情况,因此,发明人设定腔体6在电连接骨架1的表面上的最大尺寸,小于等于电连接骨架1最大外径。
在具体的实施方式中,所述腔体6在所述弯曲部4表面上的面积之和,占所述弯曲部4表面积的20%-80%。
如图2-图4所示,腔体6在弯曲部4表面上的面积之和,是指多个腔体6在弯曲部4表面上的面积相加。为了验证腔体6在弯曲部4表面上的面积之和占弯曲部4表面积的比例,对电能传输系统的弯曲部4的温升和击穿电压的影响,发明人做了一系列实验,选用相同尺寸的电连接骨架1和绝缘层2,并制备了相同尺寸的弯曲部4,将弯曲部4上设置大小相同的腔体6,数量不一致,腔体6在弯曲部4表面上的面积之和也就不一致,分别测试弯曲部4的温升和耐击穿电压,将结果记录在表2。
弯曲部4的温升的测试方法:将弯曲部4封闭在相同大小的密闭空间中,并在密闭空间设置多个温度传感器,在电能传输系统未通电时,测量密闭空间内的温度值并取平
均值,然后对电能传输系统进行通稳定电流,等到密闭空间内的温度稳定后,测量密闭空间内的温度值并取平均值,将两个温度平均值相减,即是弯曲部4的温升值。在本实施例中,温升值小于50K为合格值。
弯曲部4的耐击穿电压的测试方法:对电能传输系统进行通稳定电流,并在弯曲部4的电连接骨架1和绝缘层2分别设置电极,并在两个电极通直流高压,当两个电极发生击穿时,记录当时的电压值。在本实施例中,耐击穿电压值大于2.1KV为合格值。
表6,不同的腔体6在弯曲部4表面上的面积之和占弯曲部4表面积的比例,对弯曲部4的温升和击穿电压的影响,
从上表6可以看出,当腔体6在弯曲部4表面上的面积之和占弯曲部4表面积的比例小于20%时,弯曲部4的温升值大于50K,耐击穿电压值小于2.1KV,均为不合格。当腔体6在弯曲部4表面上的面积之和占弯曲部4表面积的比例大于80%时,弯曲部4的温升值和击穿电压值上升幅度很小,但是腔体6的制作难度增大很多,并且由于腔体6较多,绝缘层2的强度降低,容易受外力影响导致凹陷或破损,因此,发明人设定腔体6在弯曲部4表面上的面积之和,占弯曲部4表面积的20%-80%。
所述腔体6的径向形状为圆形、椭圆形、多边形、扇形、棱形或梭形。使用者可以根据不同的环境和使用要求,选择不同的径向形状。
所述连接器3为充电座。如图1所示,电连接骨架1的一端与连接端子5连接后与充电座连接,连接端子5设置在连接器3中另一端可以与车载电池连接,形成一个完整的充电系统。
一种汽车,包括上述电能传输系统。
虽然已经通过例子对本发明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,而不是为了限制本发明的范围。本领域的技术人员应该理解,可在不脱离本发明的范围和精神的情况下,对以上实施例进行修改。本发明的范围由所附权利要求来限定。
Claims (18)
- 一种电能传输系统,包括至少一根电连接骨架和设置在所述电连接骨架两端的连接器,所述电连接骨架外侧设置有绝缘层,其特征在于,所述电连接骨架具有至少一个弯曲部,至少部分的所述弯曲部含有至少一个腔体,所述腔体位于所述绝缘层内壁到所述电连接骨架外周之间。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体内气压值大于所述电连接骨架所处环境的气压值。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体内包含阻挡击穿介质,所述阻挡击穿介质的介电击穿强度大于空气的介电击穿强度。
- 根据权利要求3所述的电能传输系统,其特征在于,所述阻挡击穿介质含有硅化合物、卤化合物、氮化合物、碳化合物的一种或几种。
- 根据权利要求1所述的电能传输系统,其特征在于,所述连接器包含连接端子,所述电连接骨架两端与所述连接端子电连接。
- 根据权利要求5所述的电能传输系统,其特征在于,所述连接端子的材质为铜或铜合金。
- 根据权利要求6所述的电能传输系统,其特征在于,所述电连接骨架材质为铝或铝合金,所述电连接骨架与所述连接端子通过焊接或压接的方式电连接。
- 根据权利要求1所述的电能传输系统,其特征在于,所述电连接骨架为刚性体,所述电连接骨架的抗拉强度大于75MPa。
- 根据权利要求1所述的电能传输系统,其特征在于,所述电连接骨架的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、P形、U形、V形、W形、X形、Y形、Z形、半弧形、弧形、波浪形中的一种或多种。
- 根据权利要求9所述的电能传输系统,其特征在于,所述电连接骨架的横截面有棱边时,所述棱边倒角或倒圆。
- 根据权利要求1所述的电能传输系统,其特征在于,所述弯曲部的弯曲半径大于等于所述电连接骨架最大外径的1.19倍。
- 根据权利要求1所述的电能传输系统,其特征在于,所述弯曲部为至少两个,相邻两个所述弯曲部的距离大于等于所述电连接骨架最大外径的2.6倍。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体的径向最大高度,小于等于所述绝缘层厚度的3倍。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体的径向高度,从所述腔体的中间向四周逐渐减小。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体的占所述电连接骨架表面的最大尺寸,小于等于所述电连接骨架最大外径。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体在所述弯曲部表面上的面积之和,占所述弯曲部表面积的20%-80%。
- 根据权利要求1所述的电能传输系统,其特征在于,所述腔体的径向形状为圆形、椭圆形、多边形、扇形、棱形或梭形。
- 一种汽车,其特征在于,包括如权利要求1-17任一项所述的电能传输系统。
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CN214312693U (zh) * | 2021-03-04 | 2021-09-28 | 上海艾姆倍新能源科技有限公司 | 一种大电流柔性液冷线缆 |
CN114758834A (zh) * | 2022-03-14 | 2022-07-15 | 吉林省中赢高科技有限公司 | 一种电能传输系统及一种汽车 |
CN217822167U (zh) * | 2022-03-14 | 2022-11-15 | 吉林省中赢高科技有限公司 | 一种电能传输系统及一种汽车 |
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2022
- 2022-03-14 CN CN202210248435.2A patent/CN114758834A/zh active Pending
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2023
- 2023-03-14 WO PCT/CN2023/081326 patent/WO2023174262A1/zh unknown
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US20210134483A1 (en) * | 2017-07-14 | 2021-05-06 | Autonetworks Technologies, Ltd. | Covered electrical wire and terminal-equipped electrical wire |
JP2019149242A (ja) * | 2018-02-26 | 2019-09-05 | 古河電気工業株式会社 | フラットケーブル、及びこれを用いた回転コネクタ |
CN214203298U (zh) * | 2021-03-04 | 2021-09-14 | 上海艾姆倍新能源科技有限公司 | 一种柔性液冷线缆 |
CN214312693U (zh) * | 2021-03-04 | 2021-09-28 | 上海艾姆倍新能源科技有限公司 | 一种大电流柔性液冷线缆 |
CN114758834A (zh) * | 2022-03-14 | 2022-07-15 | 吉林省中赢高科技有限公司 | 一种电能传输系统及一种汽车 |
CN217822167U (zh) * | 2022-03-14 | 2022-11-15 | 吉林省中赢高科技有限公司 | 一种电能传输系统及一种汽车 |
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