Light-weight, high-temperature-resistant and anti-electromagnetic-interference internal cable for new energy automobile

Abstract

The utility model relates to the technical field of automobile cables, in particular to a light-weight, high-temperature-resistant and anti-electromagnetic-interference internal cable for a new energy automobile. Comprising a conductor, an insulating layer, a shielding layer and a sheath layer, the conductor is formed by regularly twisting or bunching a plurality of aluminum-magnesium-silicon alloy wires at one time according to a pitch diameter ratio of 8-10 times; the insulating layer coats the outer side of the conductor and is lapped by a polyimide film, and the lapping rate is 66%-75%; the shielding layer is coated outside the insulating layer and is of a double-layer shielding structure formed by an anti-electromagnetic permalloy wire material and tinned copper-clad steel; the permalloy wire is a braid layer made of 45%-50% Ni-Fe alloy; the tinned copper-clad steel is woven in a two-lap-two mode; and the sheath layer coats the outer side of the shielding layer. The weight of the cable is reduced, the high temperature resistance of the cable is improved, electromagnetic interference is effectively resisted, the service life of the cable is prolonged, and the safety of the cable is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile cables, and in particular to an internal cable for new energy vehicles that is lightweight, high temperature resistant and resistant to electromagnetic interference. Background Art

[0002] At present, China has become the world's largest new energy vehicle production base, and its supporting related enterprises are also facing huge opportunities and challenges. With the rapid development of the new energy vehicle market, the performance requirements for cables are getting higher and higher. Traditional cables often have problems such as heavy weight, poor high temperature resistance, and weak anti-electromagnetic interference ability, which cannot meet the needs of new energy vehicles. Therefore, the development of a lightweight, high temperature resistant, and anti-electromagnetic cable has become an urgent problem to be solved. Utility Model Content

[0003] In view of the defects of the prior art, the utility model proposes an internal cable for new energy vehicles that is lightweight, high temperature resistant and resistant to electromagnetic interference, so as to solve the above technical problems.

[0004] The utility model is achieved in this way:

[0005] A lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles, comprising a conductor, an insulation layer, a shielding layer and a sheath layer;

[0006] The conductor is made of a plurality of aluminum-magnesium-silicon alloy wires, which are twisted in a regular manner or bundled at one time with a pitch ratio of 8-10 times;

[0007] The insulating layer is coated on the outside of the conductor and is wrapped with a polyimide film with an overlap rate of 66%-75%;

[0008] The shielding layer is coated outside the insulating layer and is a double-layer shielding structure formed by an anti-electromagnetic Permalloy wire material and a tinned copper-clad steel on the outside; the Permalloy wire is a braided layer made of 45% to 50% Ni-Fe alloy; the tinned copper-clad steel is woven in a 2-over-2 manner;

[0009] The sheath layer is coated on the outside of the shielding layer.

[0010] Furthermore, the number of the aluminum-magnesium-silicon alloy wires is 19, and the diameter is 0.16 mm.

[0011] Furthermore, the polyimide film has a width of 8 mm to 10 mm and a thickness of 0.035 mm.

[0012] Furthermore, the braiding density of the Permalloy wire is above 90% to improve the anti-electromagnetic interference capability of the cable.

[0013] Furthermore, the braiding density of the tinned copper clad steel is above 80%.

[0014] Furthermore, the thickness of the sheath layer is 0.6mm-1.0mm.

[0015] The utility model has the following advantages and technical effects:

[0016] The utility model adopts 19 / 0.16mm high-conductivity aluminum-magnesium-silicon alloy wire as a conductor, which reduces the weight of the cable and improves the energy utilization efficiency and driving performance of new energy vehicles.

[0017] The high-temperature resistant polyimide material with a wrapped structure is used as the insulation layer, which improves the high-temperature resistance of the cable. It is light in weight, small in size, and has good flexibility, enabling it to work normally in a high temperature environment of 150 degrees, improving the safety and reliability of new energy vehicles.

[0018] The use of anti-electromagnetic Permalloy wire material and tinned copper clad steel composite shielding layer can effectively resist electromagnetic interference, improve the cable's anti-electromagnetic interference ability, and ensure the stable operation of new energy vehicles.

[0019] The flame-retardant and weather-resistant fluororubber material is used as the sheath layer to protect the cable from the external environment and improve the service life and safety of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic cross-sectional view of the internal cable of the utility model.

[0021] In the figure: 1. Conductor; 2. Insulation layer; 3. Shielding layer; 4. Sheath layer. DETAILED DESCRIPTION

[0022] In order to make the purpose, technical solution and advantages of the utility model more clear, the utility model is further described in detail in combination with the embodiments below. It should be understood that the specific embodiments described here are only used to explain the utility model, and are not used to limit the utility model.

[0023] like Figure 1 As shown, the utility model discloses a lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles, comprising a conductor 1, an insulating layer 2, a shielding layer 3 and a sheath layer 4.

[0024] The conductor 1 is composed of 19 high-conductivity aluminum-magnesium-silicon alloy wires with a diameter of 0.16 mm, which are twisted or bundled at one time with a pitch ratio of 8-10 times. The aluminum-magnesium-silicon alloy wire conductor is lighter than the traditional copper conductor, which further reduces the weight of the cable.

[0025] The insulating layer 2 is coated on the outside of the conductor and is made of a polyimide material. The material has excellent heat resistance, insulation and mechanical properties and can withstand high temperature environments without damage. Specifically, the insulating layer is wrapped with a polyimide film with a width of 8mm-10mm and a thickness of 0.035mm, and the overlap rate is 66%-75%. The high overlap rate ensures the thickness of the insulation and further improves the reliability of the insulation performance. Compared with the common extruded insulation structure, the wrapped structure is light in weight, small in size, flexible and easy to operate.

[0026] The shielding layer 3 is coated on the outside of the insulating layer 2, and is a double-layer shielding structure formed by an anti-electromagnetic Permalloy wire material and tinned copper-clad steel; wherein the inner layer is an anti-electromagnetic Permalloy wire, and the outer layer is a tinned copper-clad steel. The double-layer composite layer composed of different metal materials can form multiple shielding reflection interfaces, improve the shielding effectiveness of the cable, and form an anti-electromagnetic shielding structure. The Permalloy wire is a 45% to 50% Ni-Fe alloy, woven by a fiber wire weaving machine, with a weaving density of 90% or more, to improve the anti-electromagnetic interference ability of the cable; the tinned copper-clad steel is woven in a 2-over-2 manner, woven by a metal weaving machine, with a weaving density of 80% or more, to further improve the shielding effect. Alloy wire is used instead of alloy tape to increase softness. The anti-electromagnetic Permalloy wire has a shielding effect in the low frequency band and resists electromagnetic interference in the high frequency band. The tinned copper-clad steel has a high conductivity, which improves the shielding effectiveness in the high frequency band and improves the anti-interference ability of the cable.

[0027] The sheath layer 4 is a layer of flame-retardant and weather-resistant fluororubber material coated on the outside of the shielding layer 3, which has good weather resistance, oil resistance, chemical corrosion resistance and flame retardancy, and protects the cable from the external environment. The thickness of the sheath layer is 0.6mm-1.0mm.

[0028] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles, comprising a conductor, an insulating layer, a shielding layer and a sheath layer; characterized in that: The conductor is made of a plurality of aluminum-magnesium-silicon alloy wires, which are twisted in a regular manner or bundled at one time with a pitch ratio of 8-10 times; The insulating layer is coated on the outside of the conductor and is wrapped with a polyimide film with an overlap rate of 66%-75%; The shielding layer is coated outside the insulating layer and is a double-layer shielding structure formed by an anti-electromagnetic Permalloy wire material and a tinned copper-clad steel on the outside; the Permalloy wire is a braided layer made of 45% to 50% Ni-Fe alloy; the tinned copper-clad steel is woven in a 2-over-2 manner; The sheath layer is coated on the outside of the shielding layer.

2. The lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles according to claim 1, characterized in that: The number of the aluminum-magnesium-silicon alloy wires is 19, and the diameter is 0.16 mm.

3. The lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles according to claim 1, characterized in that: The polyimide film has a width of 8 mm to 10 mm and a thickness of 0.035 mm.

4. The lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles according to claim 1, characterized in that: The braiding density of the permalloy wire is above 90%.

5. The lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles according to claim 1, characterized in that: The braiding density of the tinned copper clad steel is above 80%.

6. The lightweight, high temperature resistant and electromagnetic interference resistant internal cable for new energy vehicles according to claim 1, characterized in that: The thickness of the sheath layer is 0.6mm-1.0mm.

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