High-conductivity and high-durability aluminum conductor for new energy automobile wire harness and processing method of high-conductivity and high-durability aluminum conductor

Abstract

The invention relates to the technical field of new energy automobile wire harness conductors, in particular to a high-conductivity and high-durability aluminum conductor for a new energy automobile wire harness and a processing method thereof.The high-conductivity and high-durability aluminum conductor comprises a metal conductor made of aluminum alloy and an insulating layer arranged on the outer side of the metal conductor in a sleeving mode, and a metal shielding layer is arranged on the outer side of the insulating layer in a sleeving mode; and the outer side of the metal shielding layer is sleeved with an outer sheath. According to the high-conductivity and high-durability aluminum conductor for the new energy automobile wire harness and the processing mode of the high-conductivity and high-durability aluminum conductor, the conductivity of aluminum alloy can be remarkably improved to exceed 60% IACS, and energy loss in the electric energy transmission process is effectively reduced; a 125 DEG C modified nylon 12 material is adopted, so that the working temperature grade of the cable and the adhesiveness of an insulating material and a conductor are improved, the working temperature of the cable can reach 125 DEG C, and the peeling strength of the insulating material and the conductor reaches MPa; a totally-enclosed metal shielding structure is adopted, so that the shielding efficiency of the cable is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of conductors for wiring harnesses of new energy vehicles, and in particular to a high-conductivity and high-durability aluminum conductor for wiring harnesses of new energy vehicles and a processing method thereof. Background Art

[0002] With the rapid development of new energy vehicles, the requirements for vehicle endurance, energy efficiency and environmental protection performance are increasing. As a vital component of new energy vehicles, the performance of cables directly affects the energy transmission efficiency of the entire vehicle.

[0003] In traditional technology, copper conductors are widely used in cable manufacturing due to their high electrical conductivity. However, the high density and cost of copper materials limit their application potential in lightweight and cost control. Although aluminum conductors have low density and cost advantages, their electrical conductivity is usually lower than that of copper. The electrical conductivity of traditional aluminum alloys is usually lower than the international annealed copper standard of 59%, which limits their application in the field of high-energy transmission. Therefore, without sacrificing mechanical properties and machinability, improving the electrical conductivity of aluminum alloys has become an urgent problem that needs to be solved in the industry.

[0004] In the prior art, some improved methods attempt to improve the electrical conductivity of aluminum alloys by adding rare earth elements or boron treatment. Although the electrical conductivity can be effectively improved, it has the disadvantages of reducing material plasticity, increasing production costs, environmental pollution, and possibly affecting the long-term stability of the material, which is not conducive to large-scale production and application.

[0005] Moreover, the protection performance of the outer end of the existing aluminum conductor is limited, and the internal heat dissipation is mostly passive, resulting in very limited durability, pressure resistance and bending resistance. Summary of the invention

[0006] The technical problem to be solved by the present invention is that the current aluminum alloy has high cost, low heat dissipation effect and low stability.

[0007] The technical solution adopted by the present invention to solve its technical problems is: a high-conductivity and high-durability aluminum conductor for new energy vehicle wiring harness, including a metal conductor made of aluminum alloy and an insulating layer sleeved on the outside of the metal conductor, a metal shielding layer sleeved on the outside of the insulating layer, an outer sheath sleeved on the outside of the metal shielding layer, and arc-shaped lateral heat dissipation plates with an integral structure protruding outward on both sides of the metal conductor. The arc-shaped lateral heat dissipation plates on both sides of the insulating layer form diversion and heat dissipation chambers on both sides of the metal conductor. The arc-shaped lateral heat dissipation plates on both sides of the metal conductor are provided with side-arranged diversion holes inside, and lateral metal diversion nozzles are plugged and fixed inside the diversion holes at the joint positions at both ends of the metal conductor, and the lateral metal diversion nozzles are movably equipped with external diversion devices.

[0008] External supporting reset spring pieces with L-shaped structures are staggered and fixed on both sides of the arc-shaped lateral heat dissipation plate.

[0009] The external support reset spring piece includes an upper fixing frame of an N-shaped structure mounted on the upper end of the arc-shaped lateral heat dissipation plate, an upper supporting spring piece fixed to the upper end of the upper fixing frame, a lower fixing frame of an N-shaped structure mounted on the lower end of the arc-shaped lateral heat dissipation plate, and a lower supporting spring piece fixed to the lower end of the lower fixing frame.

[0010] The external support reset spring sheet and the guide hole are arranged in a staggered manner.

[0011] Pressure sensors are installed on the upper surface of the upper supporting spring piece and the lower surface of the lower supporting spring piece.

[0012] The arc-shaped lateral heat dissipation plate and the outer connecting surface of the insulation layer are provided with embedded rubber shock-absorbing strips which are fixedly assembled.

[0013] The external flow guide device includes a flexible flow guide pipe mounted on the lateral metal flow guide nozzle on the left side of one end, a flexible return pipe mounted on the lateral metal flow guide nozzle on the right side of one end, a flexible connecting pipe mounted on the left and right lateral metal flow guide nozzles on the other end, an internal flow guide cover shell fixed between the flexible flow guide pipe and the flexible return pipe, and an electrically controlled heat dissipation fan installed inside the internal flow guide cover shell.

[0014] The lateral metal flow guide nozzle includes an external threaded assembly tube inserted into the flow guide hole, an external connecting tube axially fixed on the outside of the external threaded assembly tube, an external sealing flange and an internal locking nut threadedly sleeved on the outside of the external threaded assembly tube.

[0015] The openings at both ends of the insulating layer are sleeved with external covers for closing the lateral metal flow guide nozzles at both ends.

[0016] A processing method for a high-conductivity and high-durability aluminum conductor for a new energy vehicle wiring harness comprises the following steps: adding trace elements of iron content of 0.06-0.08wt%, copper content of 0.02-0.03wt%, manganese content of ≤0.0001wt%, chromium content of ≤0.0005wt%, zinc content of ≤0.001wt%, titanium content of ≤0.008wt% and zirconium content of ≤0.0005wt% to a mixture of aluminum content of 98.9-99.1wt%, magnesium content of 0.3-0.5wt% and silicon content of 0.2-0.5wt%, extruding through a continuous casting and rolling process, heat treating in an aging furnace at 240-260°C for 8-12 hours, and then placing the mixture.

[0017] The beneficial effects of the present invention are: (1) The high-conductivity and high-durability aluminum conductor for new energy vehicle wiring harness of the present invention and its processing method can significantly improve the conductivity of aluminum alloy to more than 60% IACS, effectively reducing energy loss during power transmission; (2) The use of curved lateral heat dissipation plates on both sides enables the aluminum conductor to have excellent mechanical properties, ensuring the reliability and durability of the structural material; (3) The staggered arrangement of the guide holes can greatly increase the internal fluid travel, thereby greatly enhancing the lateral heat dissipation efficiency; (4) Connect the lateral metal guide nozzle through the outermost guide hole, and then open the external external guide device through the lateral metal guide nozzle to facilitate installation and active heat dissipation adjustment; (5) By staggering and fixing L-shaped external support reset springs on both sides of the arc-shaped lateral heat dissipation plate, and cooperating with the fluid in the diversion heat dissipation chamber on both sides of the insulation layer, the lateral support and bending resistance of the aluminum conductor can be greatly improved, thereby improving the stability and durability of the entire wiring harness; (6) The detachable structure design facilitates production and processing; (7) The arc-shaped lateral heat dissipation plate can not only improve the impact resistance of the outer side of the insulation layer, but also improve the assembly firmness of the insulation layer by using the embedded rubber shock-absorbing strip on its outer connecting surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0019] Figure 1 It is a structural schematic diagram of the present invention.

[0020] Figure 2 It is a partial schematic diagram of the metal conductor in the present invention.

[0021] Figure 3 It is a schematic diagram of the internal structure of the external flow guide device in the present invention.

[0022] Figure 4 It is a structural schematic diagram of the assembly end of the lateral metal guide nozzle in the present invention. DETAILED DESCRIPTION

[0023] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0024] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0025] Figure 1 , Figure 2 , Figure 3 and Figure 4 The high-conductivity and high-durability aluminum conductor for the wiring harness of new energy vehicles shown in the figure comprises a metal conductor 1 made of aluminum alloy and an insulating layer 2 sleeved on the outside of the metal conductor 1, a metal shielding layer 3 sleeved on the outside of the insulating layer 2, an outer sheath 4 sleeved on the outside of the metal shielding layer 3, arc-shaped lateral heat dissipation plates 5 of an integral structure protruding outward are provided on both sides of the metal conductor 1, and the arc-shaped lateral heat dissipation plates 5 are used inside the insulating layer 2 to form a diversion and heat dissipation chamber on both sides of the metal conductor 1, and the arc-shaped lateral heat dissipation plates 5 on both sides of the metal conductor 1 are provided with side-arranged diversion holes 6 inside, and lateral metal diversion nozzles 7 are fixedly inserted inside the diversion holes 6 at the joint positions at both ends of the metal conductor 1, and the lateral metal diversion nozzles 7 are movably equipped with an external diversion device 8.

[0026] External supporting reset spring pieces 9 of an L-shaped structure are staggeredly mounted and fixed on both sides of the arc-shaped lateral heat dissipation plate 5 .

[0027] The external support reset spring 9 includes an upper fixed frame 91 of an N-shaped structure mounted on the upper end of the arc-shaped lateral heat dissipation plate 5, an upper supporting spring 92 fixed to the upper end of the upper fixed frame 91, a lower fixed frame 93 of an N-shaped structure mounted on the lower end of the arc-shaped lateral heat dissipation plate 5, and a lower supporting spring 94 fixed to the lower end of the lower fixed frame 93.

[0028] The external support reset spring piece 9 and the guide hole 6 are arranged in a staggered manner.

[0029] Pressure sensors 10 are mounted on the upper surface of the upper supporting spring piece 92 and the lower surface of the lower supporting spring piece 94 .

[0030] Embedded rubber shock absorbing strips 11 are fixedly mounted on the outer connecting surfaces of the arc-shaped lateral heat dissipation plate 5 and the insulation layer 2 .

[0031] The external flow guide device 8 includes a flexible flow guide tube 81 mounted on the lateral metal flow guide nozzle on the left side of one end, a flexible return pipe 82 mounted on the lateral metal flow guide nozzle on the right side of one end, a flexible connecting pipe 83 mounted on the left and right lateral metal flow guide nozzles at the other end, an internal flow guide cover shell 84 fixed between the flexible flow guide tube 81 and the flexible return pipe 82, and an electrically controlled heat dissipation fan 85 installed inside the internal flow guide cover shell 84.

[0032] The lateral metal guide nozzle 7 includes an external threaded assembly tube 71 inserted into the guide hole 6, an external connecting tube 72 axially fixed on the outside of the external threaded assembly tube 71, an external sealing flange 73 and an internal locking nut 74 threadedly sleeved on the outside of the external threaded assembly tube 71.

[0033] The openings at both ends of the insulating layer 2 are covered with an external cover 12 for closing the lateral metal flow guide nozzles 7 at both ends. Embodiment 1:

[0034] The aluminum content is controlled at 99.0914wt%, the magnesium content is controlled at 0.499wt%, the silicon content is controlled at 0.317wt%, and 0.068wt% iron, 0.02wt% copper, ≤0.0001wt% manganese, ≤0.0005wt% chromium, ≤0.001wt% zinc, ≤0.008wt% titanium, and ≤0.0005wt% zirconium are added. After extrusion through continuous casting and rolling processes, it is heat treated in an aging furnace at 250℃ for 10 hours and tested after being placed for 3 days; the test results show that the conductivity of the aluminum alloy conductor reaches 60.65%IACS, the tensile strength reaches 122.1MPa, the elongation reaches 18%, and the Brinell hardness is 46.7HB. Example 2: The aluminum content is controlled at 99.0129wt%, the magnesium content is controlled at 0.484wt%, the silicon content is controlled at 0.416wt%, 0.072wt% iron, 0.03wt% copper, ≤0.0001wt% manganese, ≤0.0005wt% chromium, ≤0.001wt% zinc, ≤0.008wt% titanium, ≤0.0005wt% zirconium are added. After extrusion through continuous casting and rolling process, heat treatment is carried out in an aging furnace at 240°C for 12 hours, and the test is carried out after 5 days of placement; the test results show that the conductivity of the aluminum alloy conductor reaches 60.54%IACS, the tensile strength reaches 129.1MPa, the elongation reaches 16.5%, and the Brinell hardness is 47.4HB.

[0035] The present invention adopts a heat treatment process of aging treatment. This heat treatment process can make Mg2Si precipitate uniformly, make the structure uniform, effectively eliminate internal stress, and improve the processing performance of the alloy.

[0036] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A high-conductivity and high-durability aluminum conductor for a new energy vehicle wiring harness, comprising a metal conductor (1) made of an aluminum alloy and an insulating layer (2) sheathed on the outside of the metal conductor (1), characterized in that: The insulating layer (2) is sheathed with a metal shielding layer (3) on the outside, and the metal shielding layer (3) is sheathed with an outer sheath (4) on the outside. The metal conductor (1) has arc-shaped lateral heat dissipation plates (5) of an integral structure protruding outward on both sides. The arc-shaped lateral heat dissipation plates (5) are used inside the insulating layer (2) to form a diversion and heat dissipation chamber on both sides of the metal conductor (1). The arc-shaped lateral heat dissipation plates (5) on both sides of the metal conductor (1) are provided with lateral diversion holes (6) inside. The diversion holes (6) at the joint positions at both ends of the metal conductor (1) are plugged and fixed with lateral metal diversion nozzles (7). The lateral metal diversion nozzles (7) are movably equipped with external diversion devices (8).

2. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized in that: External supporting reset spring pieces (9) of an L-shaped structure are staggeredly mounted and fixed on both sides of the arc-shaped lateral heat dissipation plate (5).

3. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 2 is characterized by: The external support reset spring piece (9) comprises an upper fixing frame (91) of an N-shaped structure sleeved on the upper end of the arc-shaped lateral heat dissipation plate (5), an upper supporting spring piece (92) fixed to the upper end of the upper fixing frame (91), a lower fixing frame (93) of an N-shaped structure sleeved on the lower end of the arc-shaped lateral heat dissipation plate (5), and a lower supporting spring piece (94) fixed to the lower end of the lower fixing frame (93).

4. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized in that: The external support reset spring sheet (9) and the guide hole (6) are arranged in a staggered manner.

5. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 3 is characterized by: Pressure sensors (10) are installed on the upper surface of the upper supporting spring sheet (92) and the lower surface of the lower supporting spring sheet (94).

6. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized by: The arc-shaped lateral heat dissipation plate (5) and the outer connecting surface of the insulating layer (2) are provided with embedded rubber shock-absorbing strips (11) fixedly mounted thereon.

7. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized by: The external flow guide device (8) comprises a flexible flow guide pipe (81) mounted on a lateral metal flow guide nozzle on the left side of one end, a flexible return pipe (82) mounted on a lateral metal flow guide nozzle on the right side of one end, a flexible connecting pipe (83) mounted on the left and right lateral metal flow guide nozzles on the other end, an internal flow guide housing (84) fixed between the flexible flow guide pipe (81) and the flexible return pipe (82), and an electrically controlled heat dissipation fan (85) installed inside the internal flow guide housing (84).

8. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized by: The lateral metal flow guide nozzle (7) comprises an externally threaded assembly tube (71) inserted into the flow guide hole (6), an external connection tube (72) axially fixed to the outside of the externally threaded assembly tube (71), an external sealing flange (73) and an internal locking nut (74) threadedly sleeved on the outside of the externally threaded assembly tube (71).

9. The high conductivity and high durability aluminum conductor for new energy vehicle wiring harness according to claim 1 is characterized by: The openings at both ends of the insulating layer (2) are sleeved with an external cover shell (12) for closing the lateral metal flow guide nozzles (7) at both ends.

10. A processing method for high conductivity and high durability aluminum conductor for new energy vehicle wiring harness, characterized in that: Trace elements of iron content of 0.06-0.08wt%, copper content of 0.02-0.03wt%, manganese content of ≤0.0001wt%, chromium content of ≤0.0005wt%, zinc content of ≤0.001wt%, titanium content of ≤0.008wt% and zirconium content of ≤0.0005wt% are added to a mixture with aluminum content of 98.9-99.1wt%, magnesium content of 0.3-0.5wt% and silicon content of 0.2-0.5wt%, after extrusion through continuous casting and rolling process, heat treatment is carried out in an aging furnace at 240℃-260℃ for 8-12 hours, and then placed for treatment.

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