Novel high-strength lightweight composite conductor automobile low-voltage wire

Abstract

The invention provides a novel high-strength lightweight composite conductor automobile low-voltage wire, and relates to the technical field of automobile wires and cables. The composite conductor automobile low-voltage wire comprises a composite conductor composed of high-strength copper-clad steel and copper wires, the composite conductor is formed by composite stranding of the high-strength copper-clad steel and the copper wires and is of a multi-strand stranded structure, the outer wall of the composite conductor is wrapped with a high-temperature-resistant middle layer, the outer wall of the middle layer is wrapped with an enhanced protection layer, and the outer wall of the enhanced protection layer is wrapped with a high-temperature-resistant outer layer. The outer wall of the enhanced protective layer is wrapped with an insulating layer which is light, high in toughness, resistant to high temperature and resistant to abrasion. According to the invention, through a composite conductor material and a unique manufacturing process, the tensile strength of the automobile low-voltage wire is remarkably improved, and compared with a traditional automobile low-voltage wire, the tensile strength can be improved by 30%-50%, the automobile low-voltage wire can bear a more complex external force environment, wire damage caused by external force is reduced, and the reliability of an automobile electrical system is improved.

Description

Technical Field

[0001] The invention relates to the technical field of automobile wires and cables, in particular to a novel high-strength and lightweight composite conductor automobile low-voltage wire. Background Art

[0002] With the development of the automobile industry and the advancement of technology, car owners have higher requirements for car safety and comfort, integrated circuits and microcomputers are widely used in cars, the number of electrical appliances increases, the space for laying wires in the car decreases, and the weight of the car increases.

[0003] As the automotive industry moves towards lightweighting, the heavy weight of traditional low-voltage cables has become an obstacle to vehicle weight reduction. This is because traditional manufacturing processes do not fully consider material selection and structural design, resulting in the difficulty of reducing the weight of cables while meeting the conductivity requirements, which is not conducive to improving vehicle fuel economy and electric vehicle range.

[0004] Traditional automotive low-voltage wires are often damaged due to external forces such as vibration, friction, and stretching in the complex operating environment of the car. The main reason is that the strength of the conductor material is limited and cannot meet the requirements of modern cars for the resistance of wires to external forces, affecting the stability of the automotive electrical system. In addition, the use of some high-strength materials will lead to a significant increase in costs, while some low-cost manufacturing processes cannot guarantee product quality. The existing manufacturing process has obvious deficiencies in balancing product quality and cost, and it is difficult to meet the dual needs of performance and price in market competition.

[0005] Therefore, those skilled in the art provide a novel high-strength and lightweight composite conductor automotive low-voltage line to solve the problems raised in the above background technology. Summary of the invention

[0006] 1. Technical issues to be solved

[0007] In view of the deficiencies in the prior art, the present invention provides a new type of high-strength and lightweight composite conductor automotive low-voltage wire, which solves the problem that the traditional manufacturing process does not fully consider the selection of materials and structural design, resulting in the wire being difficult to reduce in weight while meeting the conductive properties, which is not conducive to improving the fuel economy of the vehicle and the cruising range of the electric vehicle.

[0008] (II) Technical solution

[0009] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0010] A new type of high-strength and lightweight composite conductor automotive low-voltage line, including a composite conductor composed of high-strength copper-clad steel and copper wire. The composite conductor is made of high-strength copper-clad steel and copper wire and is a multi-strand twisted structure. The outer wall of the composite conductor is wrapped with a high-temperature resistant intermediate layer, the outer wall of the intermediate layer is wrapped with a reinforced protective layer, and the outer wall of the reinforced protective layer is wrapped with a lightweight, high-toughness, high-temperature resistant, and wear-resistant insulating layer.

[0011] Preferably, the composite conductor has a lay length of 8 to 10 mm, a tensile strength of >500 MPa, and a cross-sectional area of ​​0.19 mm 2 .

[0012] Preferably, the intermediate layer is an aluminum-based material with high heat resistance.

[0013] Preferably, the light-weight, high-toughness, high-temperature-resistant and wear-resistant insulating layer is made of one or more combinations of PVC, PP, XLPE, FEP, foamed PP, foamed PE and PA.

[0014] Preferably, the outer insulating layer may also be made of environmentally friendly plastic materials that are resistant to high temperatures and UV rays, such as polyethylene and polyvinyl chloride, and a special waterproof and fireproof protective layer may be designed according to different working environment requirements.

[0015] Preferably, the copper-clad steel comprises the following components: 18% to 22% copper, 75% to 78% steel, and 2% to 5% graphite powder, and the preparation method of the copper-clad steel is:

[0016] 1) Pretreatment: soak the selected steel wire in an acid solution with a mass concentration of 50-60% for 15-20 minutes, grind and polish it, then put it in anhydrous ethanol for ultrasonic treatment for 5-10 minutes, take it out and rinse it with anhydrous ethanol, and then dry it;

[0017] 2) Preheating: preheating the pretreated steel wire in an inert atmosphere at 400-500° C. for 20-40 min, then immersing the steel wire in molten copper for 40-50 min in an inert atmosphere, and cooling to room temperature to obtain a copper-clad steel wire blank;

[0018] 3) Post-treatment: After the copper-clad steel wire blank is heated and softened, it is subjected to multiple forming and drawing, and then quenched by a treatment liquid at a quenching cooling rate of 0.5-1.0°C / min to obtain a finished copper-clad steel wire.

[0019] Preferably, the composition of the insulating layer includes the following components in parts by weight: 20 to 30 parts of PVC, 15 to 20 parts of PP, 10 to 15 parts of XLPE, 8 to 10 parts of FEP, 6 to 8 parts of foamed PP, 4 to 6 parts of foamed PE, and 9 to 13 parts of PA, and the preparation method of the insulating layer is as follows:

[0020] 1) Raw material mixing: PVC resin, PP, XLPE, FEP, foamed PP, foamed PE, PA, etc. are mixed with plasticizers, stabilizers, and fillers in a certain proportion to make a uniform mixture;

[0021] 2) Extrusion: The mixture is heated and plasticized by an extruder, and then passed through an extrusion die to form a PVC insulation layer, and then cooled to obtain the required wire insulation layer;

[0022] 3) Cooling: Use water cooling system or air cooling to shape the insulation layer;

[0023] 4) Cutting: Cut the shaped insulation layer into appropriate lengths for further use in cable production.

[0024] Preferably, a method for preparing a high-strength and lightweight composite conductor automotive low-voltage wire comprises the following steps:

[0025] Step S1. Prepare high-strength copper-clad steel wire and copper wire;

[0026] Step S2. The copper-clad steel wire and the copper wire are twisted into a shape by a special twisting process, with a twisting distance of 8 to 10 mm, and a compacting mold is used to ensure that the copper wire is tightly wrapped on the copper-clad steel wire, and the wrapping is tight and firm, so as to obtain a composite conductor;

[0027] Step S3. Wrapping an aluminum-based material with high heat resistance around the outside of the composite conductor to form an intermediate layer;

[0028] Step S4. Wrapping the middle layer with a reinforced protective layer;

[0029] Step S5. Wrap a lightweight, high-toughness, high-temperature-resistant, and wear-resistant material around the outside of the enhanced protective layer to form an insulating layer, thereby obtaining a high-strength and lightweight composite conductor automotive low-voltage line.

[0030] After the automotive low-voltage line is manufactured, the quality inspection process also includes:

[0031] 1) Carry out a comprehensive inspection of the low-voltage wires of automobiles after being coated with the insulation layer;

[0032] 2) The strength of the conductor is tested through a tensile test, and the tensile strength is required to reach 400N / mm 2 above;

[0033] 3) Use an insulation resistance tester to test the insulation performance. The insulation resistance should not be less than 1000MΩ·km;

[0034] 4) Use high-precision measuring instruments to check the dimensional accuracy of the wires to ensure that the outer diameter, inner diameter and other dimensions are within the specified tolerance range.

[0035] (III) Beneficial effects

[0036] The present invention provides a new type of high-strength and lightweight composite conductor automotive low-voltage line. It has the following beneficial effects:

[0037] 1. The present invention provides a new type of high-strength and lightweight composite conductor automotive low-voltage wire. Through the composite conductor material and unique manufacturing process, the tensile strength of the automotive low-voltage wire is significantly improved. Compared with the traditional automotive low-voltage wire, the tensile strength can be increased by 30% to 50%. It can withstand more complex external force environments, reduce wire damage caused by external forces, and improve the reliability of the automotive electrical system.

[0038] 2. The present invention provides a new type of high-strength and lightweight composite conductor automotive low-voltage wire. The use of new insulating materials and composite conductors greatly reduces the weight of the wires, effectively reducing the weight of the wires. Compared with traditional products, the weight can be reduced by 20% to 30%, which is helpful for the lightweight design of automobiles and improves fuel economy or the cruising range of electric vehicles.

[0039] 3. The present invention provides a new type of high-strength and lightweight composite conductor automotive low-voltage line, which reduces unnecessary processing steps and intermediate links by integrating production links, optimizing the production process, and reducing production costs. At the same time, it establishes multiple quality inspection processes and conducts inspections after each key production link, including conductor strength test, insulation performance test, dimensional accuracy test, etc. The strict quality inspection process ensures product quality. The reduction in scrap rate and the improvement in production efficiency make the product have a price advantage in the market, and high-quality products can reduce after-sales maintenance costs and improve the company's economic benefits and market competitiveness. DETAILED DESCRIPTION

[0040] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] Example:

[0042] An embodiment of the present invention provides a novel high-strength and lightweight composite conductor automotive low-voltage line, comprising a composite conductor composed of high-strength copper-clad steel and copper wire, wherein the composite conductor is formed by composite twisting of high-strength copper-clad steel and copper wire, and is a multi-strand twisted structure, wherein the outer wall of the composite conductor is wrapped with a high-temperature resistant intermediate layer, the outer wall of the intermediate layer is wrapped with a reinforced protective layer, and the outer wall of the reinforced protective layer is wrapped with a lightweight, high-toughness, high-temperature resistant, and wear-resistant insulating layer.

[0043] The composite conductor has a lay length of 8-10 mm, a tensile strength of >500 MPa, and a cross-sectional area of ​​0.19 mm 2 , use 0.19mm 2 The new composite conductor can replace the original 0.35mm 2 The pure copper conductor has good strength and light weight. The composite conductor adopts a multi-strand twisted structure to reduce the risk of conductor breakage under vibration and tension and improve structural strength.

[0044] And on the basis of meeting the conductivity requirements, the weight is further reduced and good tensile strength is ensured by optimizing the cross-sectional area and shape of the composite conductor.

[0045] The intermediate layer is an aluminum-based material with high heat resistance. The aluminum-based material, which is lightweight and has good conductivity, is used as the core material of the conductor, combined with copper alloy or other high-performance metal materials to improve the mechanical strength and electrical conductivity of the conductor.

[0046] A reinforced protective layer is added on the outside to enhance impact resistance and corrosion resistance, ensuring long-term use of the wires in extreme environments.

[0047] The lightweight, high-toughness, high-temperature-resistant and wear-resistant insulating layer material is made of one or more combinations of PVC, PP, XLPE, FEP, foamed PP, foamed PE and PA. Lightweight, high-toughness, high-temperature-resistant and wear-resistant PVC, PP, XLPE, FEP, foamed PP, foamed PE and PA are used as the insulating layer, which reduces the weight of the insulating layer while enhancing its protection capability in complex environments.

[0048] The external insulating layer can also be made of environmentally friendly plastic materials that are resistant to high temperatures and ultraviolet rays, such as polyethylene and polyvinyl chloride, and a special waterproof and fireproof protective layer can be designed according to different working environment requirements.

[0049] The copper-clad steel comprises the following components: 20% copper, 77% steel, and 3% graphite powder, and the preparation method of the copper-clad steel is:

[0050] 1) Pretreatment: The selected steel wire is immersed in an acid solution with a mass concentration of 55% for 20 minutes, polished, and then ultrasonicated in anhydrous ethanol for 10 minutes. After being taken out, it is rinsed with anhydrous ethanol and then dried;

[0051] 2) Preheating: preheating the pretreated steel wire at 450° C. in an inert atmosphere for 30 min, then immersing the steel wire in molten copper for 45 min in an inert atmosphere, and cooling to room temperature to obtain a copper-clad steel wire blank;

[0052] 3) Post-treatment: After the copper-clad steel wire blank is heated and softened, it is subjected to multiple forming and drawing, and then quenched by a treatment liquid at a quenching cooling rate of 1.0°C / min to obtain a finished copper-clad steel wire.

[0053] Through quenching treatment, the steel-clad wire can avoid excessive brittleness while ensuring hardness and strength, thereby improving tensile strength and fatigue resistance.

[0054] The components of the insulating layer include the following components in parts by weight: 25 parts of PVC, 18 parts of PP, 12 parts of XLPE, 9 parts of FEP, 7 parts of foamed PP, 5 parts of foamed PE, and 11 parts of PA, and the preparation method of the insulating layer is as follows:

[0055] 1) Raw material mixing: PVC resin, PP, XLPE, FEP, foamed PP, foamed PE, PA, etc. are mixed with plasticizers, stabilizers, and fillers in a certain proportion to make a uniform mixture;

[0056] 2) Extrusion: The mixture is heated and plasticized by an extruder, and then passed through an extrusion die to form a PVC insulation layer, and then cooled to obtain the required wire insulation layer;

[0057] 3) Cooling: Use water cooling system or air cooling to shape the insulation layer;

[0058] 4) Cutting: Cut the shaped insulation layer into appropriate lengths for further use in cable production.

[0059] The method for preparing the high-strength lightweight composite conductor automotive low-voltage wire comprises the following steps:

[0060] Step S1. Prepare high-strength copper-clad steel wire and copper wire;

[0061] Step S2. The copper-clad steel wire and the copper wire are twisted into a shape by a special twisting process, with a twisting distance of 10 mm, and a compacting mold is used to ensure that the copper wire is tightly wrapped on the copper-clad steel wire, and the wrapping is tight and firm, so as to obtain a composite conductor;

[0062] Step S3. Wrapping an aluminum-based material with high heat resistance around the outside of the composite conductor to form an intermediate layer;

[0063] Step S4. Wrapping the middle layer with a reinforced protective layer;

[0064] Step S5. Wrap a lightweight, high-toughness, high-temperature-resistant, and wear-resistant material around the outside of the enhanced protective layer to form an insulating layer, thereby obtaining a high-strength and lightweight composite conductor automotive low-voltage line.

[0065] High-speed precision extrusion technology is used to ensure the perfect combination of conductor and insulation layer, ensure the uniformity and consistency of materials, and improve the overall performance of the product;

[0066] The grain structure of the conductor material is optimized through the stretching and annealing process, the strength and ductility of the conductor are improved, thereby enhancing the tensile and fatigue resistance of the cable.

[0067] After the automotive low-voltage line is manufactured, the quality inspection process also includes:

[0068] 1) Carry out a comprehensive inspection of the low-voltage wires of automobiles after being coated with the insulation layer;

[0069] 2) The strength of the conductor is tested through a tensile test, and the tensile strength is required to reach 400N / mm 2 above;

[0070] 3) Use an insulation resistance tester to test the insulation performance. The insulation resistance should not be less than 1000MΩ·km;

[0071] 4) Use high-precision measuring instruments to check the dimensional accuracy of the wires to ensure that the outer diameter, inner diameter and other dimensions are within the specified tolerance range.

[0072] When the high-strength and lightweight composite conductor automotive low-voltage line is used in the later stage, advanced connection processes such as laser welding or ultrasonic welding are adopted to ensure that each wire and port are firmly and reliably connected, reduce the risk of poor electrical contact, and perform customized cable assembly according to the layout and electrical system requirements of different models, reduce the redundant length of wires, and improve installation efficiency and vehicle space utilization.

[0073] Through scientific and detailed design, the material usage of the wires is reduced while ensuring that the conductive performance is not affected, thus meeting the lightweight requirements. Through precise design of the insulation layer, the material thickness is reduced, the total weight is controlled, and the impact on the overall weight of the vehicle is reduced.

[0074] During the production process, automated testing equipment is set up to monitor the conductivity, insulation strength, tensile strength and other parameters of the cable in real time to ensure the quality of each cable. The finished low-voltage lines are subjected to environmental tests such as temperature, humidity, stretching, and impact to ensure their stability and reliability in long-term use.

[0075] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A new type of high-strength and lightweight composite conductor automotive low-voltage line, characterized in that: The invention comprises a composite conductor composed of high-strength copper-clad steel and copper wire, wherein the composite conductor is formed by composite twisting of high-strength copper-clad steel and copper wire and has a multi-strand twisted structure, wherein the outer wall of the composite conductor is wrapped with a high-temperature resistant intermediate layer, the outer wall of the intermediate layer is wrapped with a reinforced protective layer, and the outer wall of the reinforced protective layer is wrapped with a lightweight, high-toughness, high-temperature resistant and wear-resistant insulating layer.

2. A novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1, characterized in that: The composite conductor has a lay length of 8-10 mm, a tensile strength of >500 MPa, and a cross-sectional area of ​​0.19 mm 2 .

3. The novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1 is characterized in that: The middle layer is an aluminum-based material with high heat resistance.

4. The novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1 is characterized in that: The light-weight, high-toughness, high-temperature-resistant and wear-resistant insulating layer is made of one or more combinations of PVC, PP, XLPE, FEP, foamed PP, foamed PE and PA.

5. The novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1 is characterized in that: The external insulating layer can also be made of environmentally friendly plastic materials that are resistant to high temperatures and ultraviolet rays, such as polyethylene and polyvinyl chloride, and a special waterproof and fireproof protective layer can be designed according to different working environment requirements.

6. The novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1 is characterized in that: The copper-clad steel comprises the following components: 18% to 22% copper, 75% to 78% steel, and 2% to 5% graphite powder, and the preparation method of the copper-clad steel is: 1) Pretreatment: soak the selected steel wire in an acid solution with a mass concentration of 50-60% for 15-20 minutes, grind and polish it, then put it in anhydrous ethanol for ultrasonic treatment for 5-10 minutes, take it out and rinse it with anhydrous ethanol, and then dry it; 2) Preheating: preheating the pretreated steel wire in an inert atmosphere at 400-500° C. for 20-40 min, then immersing the steel wire in molten copper for 40-50 min in an inert atmosphere, and cooling to room temperature to obtain a copper-clad steel wire blank; 3) Post-treatment: After the copper-clad steel wire blank is heated and softened, it is subjected to multiple forming and drawing, and then quenched by a treatment liquid at a quenching cooling rate of 0.5-1.0°C / min to obtain a finished copper-clad steel wire.

7. The novel high-strength and lightweight composite conductor automotive low-voltage line according to claim 1 is characterized in that: The components of the insulating layer include the following components in parts by weight: 20 to 30 parts of PVC, 15 to 20 parts of PP, 10 to 15 parts of XLPE, 8 to 10 parts of FEP, 6 to 8 parts of foamed PP, 4 to 6 parts of foamed PE, and 9 to 13 parts of PA, and the preparation method of the insulating layer is as follows: 1) Raw material mixing: PVC resin, PP, XLPE, FEP, foamed PP, foamed PE, PA, etc. are mixed with plasticizers, stabilizers, and fillers in a certain proportion to make a uniform mixture; 2) Extrusion: The mixture is heated and plasticized by an extruder, and then passed through an extrusion die to form a PVC insulation layer, and then cooled to obtain the required wire insulation layer; 3) Cooling: Use water cooling system or air cooling to shape the insulation layer; 4) Cutting: Cut the shaped insulation layer into appropriate lengths for further use in cable production.

8. The method for preparing a high-strength and lightweight composite conductor automotive low-voltage wire according to claim 1, characterized in that: The following steps are involved: Step S1. Prepare high-strength copper-clad steel wire and copper wire; Step S2. The copper-clad steel wire and the copper wire are twisted into a shape by a special twisting process, with a twisting distance of 8 to 10 mm, and a compacting mold is used to ensure that the copper wire is tightly wrapped on the copper-clad steel wire, and the wrapping is tight and firm, so as to obtain a composite conductor; Step S3. Wrapping an aluminum-based material with high heat resistance around the outside of the composite conductor to form an intermediate layer; Step S4. Wrapping the middle layer with a reinforced protective layer; Step S5. Wrap a lightweight, high-toughness, high-temperature-resistant, and wear-resistant material around the outside of the enhanced protective layer to form an insulating layer, thereby obtaining a high-strength and lightweight composite conductor automotive low-voltage line.

9. The method for preparing a high-strength and lightweight composite conductor automotive low-voltage wire according to claim 8, characterized in that: After the automotive low-voltage line is manufactured, the quality inspection process also includes: 1) Carry out a comprehensive inspection of the low-voltage wires of automobiles after being coated with the insulation layer; 2) The strength of the conductor is tested through a tensile test, and the tensile strength is required to reach 400N / mm 2 above; 3) Use an insulation resistance tester to test the insulation performance. The insulation resistance should not be less than 1000MΩ·km; 4) Use high-precision measuring instruments to check the dimensional accuracy of the wires to ensure that the outer diameter, inner diameter and other dimensions are within the specified tolerance range.