A manufacturing process for high-strength and lightweight automotive low-voltage wire

Abstract

The present invention provides a manufacturing process of a high-strength and lightweight automotive low-voltage line, and relates to the technical field of automotive wires and cables. The manufacturing process of the automotive low-voltage line comprises the following steps: step S1. preparing conductor materials tinned copper and aluminum alloy copper-clad aluminum; step S2. twisting the tinned copper wire and the aluminum alloy copper-clad aluminum wire into a shape, with a twist pitch of 8-10mm, using a compacting mold to ensure that the copper wire is tightly wrapped on the copper-clad steel wire, and the wrapping is tight and firm to form a composite conductor; step S3. performing a back-twisting operation on the formed composite conductor, and achieving 100% back-twisting of each copper wire. In the present invention, through reasonable material selection and process optimization, the cost is effectively controlled while achieving high performance. Although the new materials and processes may have a certain investment in the early stage, in the long run, due to the improvement of product quality, the after-sales maintenance cost is reduced, and the overall cost of the vehicle brought about by lightweighting is reduced, such as reduced fuel consumption and improved battery life, etc., it has good economic benefits.

Description

Technical Field

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

[0002] Automotive wires are an indispensable and important component in automotive electrical systems. With the extensive application of automotive electrical appliances, the continuous development and progress of automobile manufacturing technology and the emergence of people's actual needs, the number and types of automotive wires used in automobiles are increasing, and their actual use standards are also being further improved to help provide a better user experience.

[0003] The conductors of traditional low-voltage lines in automobiles are mostly made of a single metal material. In the complex use environment of automobiles, they are not strong enough and are easily damaged by external forces such as stretching, squeezing and vibration. At the same time, with the development trend of lightweight automobiles, traditional conductors are heavier, which increases the overall weight of the vehicle and affects the fuel economy and the range of electric vehicles.

[0004] In existing automotive low-voltage wires, the insulation layer and the conductor are often not tightly bonded together. Under long-term use or complex working conditions, problems such as delamination and wear may occur, affecting the service life and safety of the wires. In addition, the performance of a single material is limited. For example, pure copper conductors have good conductivity but insufficient strength, and some high-strength metals are too expensive. Moreover, the current composite conductor design is insufficient in combining the advantages of different materials, fails to fully meet the dual requirements of high strength and lightweight for automotive low-voltage wires, and lacks effective cost control.

[0005] Therefore, those skilled in the art provide a manufacturing process for a high-strength and lightweight automotive low-voltage wire to solve the problems raised in the above background technology. Summary of the invention

[0006] 1. Technical issues to be resolved

[0007] In view of the deficiencies in the prior art, the present invention provides a manufacturing process for high-strength and lightweight automotive low-voltage wires, which solves the problem that the conductors of traditional automotive low-voltage wires are mostly made of a single metal material, have insufficient strength in the complex use environment of automobiles, and are easily damaged by external forces such as stretching, extrusion and vibration.

[0008] (II) Technical solution

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

[0010] A manufacturing process of a high-strength and lightweight automotive low-voltage wire comprises the following steps:

[0011] Step S1. Prepare conductor materials tinned copper and aluminum alloy copper clad aluminum;

[0012] Step S2. Twisting the tinned copper wire and the aluminum alloy copper-clad aluminum wire into a composite conductor with a twist length of 8-10 mm and using a compacting die to ensure that the copper wire is tightly wrapped around the copper-clad steel wire, tightly and firmly wrapped to form a composite conductor;

[0013] Step S3. performing a detwisting operation on the formed composite conductor, and achieving 100% detwisting of each copper wire;

[0014] Step S4. Place the stranded composite conductor into an annealing furnace, heat to an annealing temperature at a certain heating rate, keep the temperature for 1-2 hours for annealing, and then slowly cool to room temperature;

[0015] Step S5. Using an extrusion coating process, extrude the insulating material particles at a high temperature to obtain an insulating material;

[0016] Step S6. Extruding the insulating material onto the outside of the composite conductor using an extruder to form an insulating layer;

[0017] Step S7. Extruding a polyvinyl chloride material on the outside of the anti-interference layer to form an outer protective layer, thereby obtaining a high-strength and lightweight automotive low-voltage wire;

[0018] Step S8. The obtained low-voltage wire is stretched and straightened. The low-voltage wire is placed in a stretching device for moderate stretching. The stretching ratio is controlled at 1%-3%. Then, a straightening device is used to straighten the twisted wires.

[0019] Preferably, the composite conductor is made of tinned copper and aluminum alloy copper clad aluminum composite twisted, and is a multi-strand wire twisted design, with a tensile strength of >500MPa and a cross-sectional area of ​​0.19mm 2 .

[0020] Preferably, the insulating material is made of a material that is resistant to high temperatures, wear and chemical corrosion, specifically including polyethylene, polyvinyl chloride, fluoroplastics and thermoplastic elastomers.

[0021] Preferably, in step S2 and step S3, the copper wires rotate together during the twisting process and contact the pay-off drum through the friction wheel, and the pay-off drum is driven by friction force to rotate in the opposite direction to achieve detwisting, and the degree of detwisting can be controlled by adjusting the pressure between the friction wheel and the pay-off drum.

[0022] Preferably, in step S4, the annealing temperature is between 300-500° C., and the annealing cooling rate is 1-2° C. / min.

[0023] Preferably, the outer protective layer is made of polyvinyl chloride material, which has strong wear resistance and corrosion resistance.

[0024] Preferably, the production of the high-strength and lightweight automotive low-voltage wire also includes comprehensive performance testing of the produced high-strength and lightweight automotive low-voltage wire, including a tensile strength test to ensure that the tensile strength is more than 30% higher than that of traditional wires, a conductivity test to meet the conductivity standards of automotive low-voltage wires, an insulation performance test to ensure that the withstand voltage level and insulation resistance meet the requirements, and a weight measurement to reduce the weight by 20% compared to traditional wires.

[0025] Preferably, after the performance test, the produced high-strength and lightweight automotive low-voltage wire needs to be optimized and adjusted. According to the test results, the production process parameters are adjusted, such as the composite temperature and pressure of the composite conductor, and the extrusion speed and temperature of the insulation layer, so as to continuously optimize product performance.

[0026] (III) Beneficial effects

[0027] The present invention provides a manufacturing process for a high-strength and lightweight automotive low-voltage wire, which has the following beneficial effects:

[0028] 1. The present invention provides a manufacturing process for a high-strength and lightweight automotive low-voltage line. The design of the new composite conductor greatly improves the tensile strength of the automotive low-voltage line, and the line can withstand greater external forces without being easily damaged, thus meeting the use requirements of complex automotive working conditions. At the same time, due to the use of lightweight materials, the overall weight of the wire is significantly reduced. Compared with traditional automotive low-voltage wires, the tensile strength can be increased by 30%-50%, and the weight can be reduced by 20%-30%, which is conducive to the lightweight design of the vehicle and improves fuel economy or the cruising range of electric vehicles.

[0029] 2. The present invention provides a manufacturing process for a high-strength and lightweight automotive low-voltage wire, in which the insulating layer and the composite conductor are tightly combined, and are not prone to problems such as delamination and wear. During long-term use, the conductor can be better protected, the service life and electrical safety of the wire are improved, and the risk of automobile safety accidents caused by wire failures is reduced.

[0030] 3. The manufacturing process of a high-strength and lightweight automotive low-voltage wire provided by the present invention effectively controls costs while achieving high performance through reasonable material selection and process optimization. Although new materials and processes may require certain investments in the early stages, in the long run, the improved product quality reduces after-sales maintenance costs, and the overall cost of the vehicle is reduced due to lightweighting, such as reduced fuel consumption and improved battery life. It has good economic benefits. At the same time, this design also improves the competitiveness of the product in the market. DETAILED DESCRIPTION

[0031] 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.

[0032] Example:

[0033] The embodiment of the present invention provides a manufacturing process of a high-strength and lightweight automotive low-voltage wire, comprising the following steps:

[0034] Step S1. Prepare conductor materials tinned copper and aluminum alloy copper clad aluminum;

[0035] Step S2. Twisting the tinned copper wire and the aluminum alloy copper-clad aluminum wire into a composite conductor with a twisting distance of 10 mm, using a compacting die to ensure that the copper wire is tightly wrapped around the copper-clad steel wire, and the wrapping is tight and firm to form a composite conductor;

[0036] Step S3. performing a detwisting operation on the formed composite conductor, and achieving 100% detwisting of each copper wire;

[0037] Step S4. Place the stranded composite conductor into an annealing furnace, heat to an annealing temperature at a certain heating rate, keep the temperature for 2 hours for annealing, and then slowly cool to room temperature;

[0038] Step S5. Using an extrusion coating process, extrude the insulating material particles at a high temperature to obtain an insulating material;

[0039] Step S6. Extruding the insulating material onto the outside of the composite conductor using an extruder to form an insulating layer;

[0040] Step S7. Extruding a polyvinyl chloride material on the outside of the anti-interference layer to form an outer protective layer, thereby obtaining a high-strength and lightweight automotive low-voltage wire;

[0041] Step S8. The obtained low-voltage wire is stretched and straightened. The low-voltage wire is placed in a stretching device for moderate stretching. The stretching ratio is controlled at 1%-3%. Then, a straightening device is used to straighten the twisted wires.

[0042] Stretching can redistribute the stress inside the wire and diffuse the stress in the local high-stress area to the surrounding area, thereby achieving the purpose of reducing the stress peak. At the same time, the straightening equipment repeatedly bends and corrects the wire through multiple sets of rollers to make the shape of the wire more regular, while also eliminating some of the bending stress caused by twisting.

[0043] The composite conductor is made of tinned copper and aluminum alloy copper clad aluminum composite twisted, and is designed as a multi-strand wire twisted, with a tensile strength of >500MPa and a cross-sectional area of ​​0.19mm 2 ;

[0044] Multi-strand conductors have strong resistance to breakage: the multi-strand twisted design can effectively prevent single-strand breakage and increase the service life of the cable;

[0045] Good flexibility: enables the cable to be used in harsh conditions such as bending and twisting without being easily damaged;

[0046] Balance between strand count and wire diameter: A design with more strands and thinner wire diameter can improve the flexibility of the cable, but resistance and durability also need to be controlled;

[0047] Twisting tightness: The twisting tightness determines the mechanical strength, bending resistance and conductivity of the cable, and needs to be optimized according to the specific use environment.

[0048] The insulating material is made of materials that are resistant to high temperatures, wear and chemical corrosion, and specifically include polyethylene, polyvinyl chloride, fluoroplastics and thermoplastic elastomers.

[0049] The insulation layer of the high-strength and lightweight low-voltage line adopts a compact multi-layer structure with uniform thickness, which can ensure the electrical performance of the cable, avoid leakage, and has strong anti-aging performance. Under the influence of high temperature, moisture and chemical media, the cable can still maintain good insulation.

[0050] In step S2 and step S3, the copper wires rotate together during the twisting process and contact the pay-off drum through the friction wheel, and the pay-off drum is driven by friction to rotate in the opposite direction to achieve detwisting, and the degree of detwisting can be controlled by adjusting the pressure between the friction wheel and the pay-off drum.

[0051] Detwisting can reduce the strain energy of the monofilament during the twisting process, and detwisting can restore the fiber structure of the monofilament to its initial state through reverse twisting, thereby releasing the strain energy and reducing the internal stress caused by twisting.

[0052] In step S4, the annealing temperature is between 300-500° C., and the annealing cooling rate is 1.5° C. / min. Within this temperature range, the activity of copper atoms is enhanced, the lattice defects inside the metal are repaired, and the stress is released.

[0053] The outer protective layer is made of polyvinyl chloride material, which has strong wear resistance and corrosion resistance. The outer protective layer can also be made of thermoplastic elastomer and silicone. Thermoplastic elastomer is used for cables that require higher flexibility, and silicone is high temperature resistant and suitable for cables that need to work in high temperature environments.

[0054] The outer sheath is made of wear-resistant, high-temperature-resistant and UV-resistant materials to adapt to complex working environments.

[0055] The production of this high-strength and lightweight automotive low-voltage wire also includes comprehensive performance testing of the produced high-strength and lightweight automotive low-voltage wire, including tensile strength testing to ensure that the tensile strength is more than 30% higher than that of traditional wires, conductivity testing to meet the conductivity standards of automotive low-voltage wires, insulation performance testing to ensure that the withstand voltage level and insulation resistance meet the requirements, and weight measurement, which is 20% lighter than traditional wires.

[0056] After the above performance test, the high-strength and lightweight automotive low-voltage wire produced needs to be optimized and adjusted. According to the test results, the production process parameters are adjusted, such as the composite temperature and pressure of the composite conductor, and the extrusion speed and temperature of the insulation layer, so as to continuously optimize product performance.

[0057] 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 manufacturing process for high-strength and lightweight automotive low-voltage wire, characterized in that: The following steps are involved: Step S1. Prepare conductor materials tinned copper and aluminum alloy copper clad aluminum; Step S2. Twisting the tinned copper wire and the aluminum alloy copper-clad aluminum wire into a composite conductor with a twist length of 8-10 mm and using a compacting die to ensure that the copper wire is tightly wrapped around the copper-clad steel wire, tightly and firmly wrapped to form a composite conductor; Step S3. performing a detwisting operation on the formed composite conductor, and achieving 100% detwisting of each copper wire; Step S4. Place the stranded composite conductor into an annealing furnace, heat to an annealing temperature at a certain heating rate, keep the temperature for 1-2 hours for annealing, and then slowly cool to room temperature; Step S5. Using an extrusion coating process, extrude the insulating material particles at a high temperature to obtain an insulating material; Step S6. Extruding the insulating material onto the outside of the composite conductor using an extruder to form an insulating layer; Step S7. Extruding a polyvinyl chloride material on the outside of the anti-interference layer to form an outer protective layer, thereby obtaining a high-strength and lightweight automotive low-voltage wire; Step S8. The obtained low-voltage wire is stretched and straightened. The low-voltage wire is placed in a stretching device for moderate stretching. The stretching ratio is controlled at 1%-3%. Then, a straightening device is used to straighten the twisted wires.

2. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: The composite conductor is made of tinned copper and aluminum alloy copper clad aluminum composite twisted, and is designed as a multi-strand wire twisted, with a tensile strength of >500MPa and a cross-sectional area of ​​0.19mm 2 .

3. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: The insulating material is made of materials that are resistant to high temperatures, wear and chemical corrosion, and specifically include polyethylene, polyvinyl chloride, fluoroplastics and thermoplastic elastomers.

4. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: In step S2 and step S3, the copper wires rotate together during the twisting process and contact the pay-off drum through the friction wheel, and the pay-off drum is driven by friction to rotate in the opposite direction to achieve detwisting, and the degree of detwisting can be controlled by adjusting the pressure between the friction wheel and the pay-off drum.

5. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: In the step S4, the annealing temperature is between 300-500° C., and the annealing cooling rate is 1-2° C. / min.

6. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: The outer protective layer is made of polyvinyl chloride material, which has strong wear resistance and corrosion resistance.

7. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 1, characterized in that: The production of this high-strength and lightweight automotive low-voltage wire also includes comprehensive performance testing of the produced high-strength and lightweight automotive low-voltage wire, including tensile strength testing to ensure that the tensile strength is more than 30% higher than that of traditional wires, conductivity testing to meet the conductivity standards of automotive low-voltage wires, insulation performance testing to ensure that the withstand voltage level and insulation resistance meet the requirements, and weight measurement, which is 20% lighter than traditional wires.

8. The manufacturing process of a high-strength and lightweight automotive low-voltage wire according to claim 7, characterized in that: After the above performance test, the high-strength and lightweight automotive low-voltage wire produced needs to be optimized and adjusted. According to the test results, the production process parameters are adjusted, such as the composite temperature and pressure of the composite conductor, and the extrusion speed and temperature of the insulation layer, so as to continuously optimize product performance.