An aluminum alloy flat cable for new energy vehicles

Abstract

The present invention discloses an aluminum alloy flat cable for new energy vehicles, which relates to the technical field of power cables. It includes an aluminum alloy solid conductor, and a composite insulation layer is arranged on the outer side of the aluminum alloy solid conductor. An aerogel thermal insulation layer is coated inside the composite insulation layer. A limiting central groove is opened inside the aerogel thermal insulation layer, and a heat-conducting silica gel sheet is clamped inside the limiting central groove. A central connecting sleeve is connected to the middle of the heat-conducting silica gel sheet. In the present invention, the heat inside the flat cable is directionally transferred through the circulation of the heat-conducting oil inside the diversion outer tube and the return inner tube, ensuring that the inside of the flat cable can be maintained within a suitable temperature range during use, and effectively preventing the heat generated during the operation of the flat cable from spreading randomly and causing abnormal temperature rise of the surrounding electronic components, affecting the normal use. It ensures that the flat cable will not affect the normal use of the vehicle during use, and effectively improves the use safety of the flat cable.

Description

Technical Field

[0001] The present invention relates to the technical field of power cables, and particularly to an aluminum alloy flat cable for new energy vehicles. Background Art

[0002] A new round of global technological and industrial revolutions is booming. The automotive industry has entered a major transformation era never seen in a century. The automotive industry is accelerating its integration with fields such as information communication and energy. The development of new energy vehicles presents both new challenges and development opportunities. For new energy vehicle companies, mastering the core technologies of "three electrics" is only a basic requirement, but it is far from enough. Motor, electric control, and battery technologies are basic technologies, and the technology of integrating the whole vehicle is more difficult and requires higher standards. The integration and manufacturing of new energy vehicle whole vehicles represent the peak of automotive technology. In the process of the development of new energy vehicles, corresponding aluminum alloy flat cables are required. For this reason, the Chinese patent discloses a flexible flat cable that is easy to connect, with the application number 202411666605.4. Through the cooperation between the plug and the socket, this patent can connect two cable units, thereby freely adjusting the length of the flat cable to meet the usage requirements of different scenarios or devices. And through the rotation of the balls and the rotation of the rollers, it is convenient to insert the plug into the socket or pull it out from the socket.

[0003] However, currently, the aluminum alloy flat cable is restricted by its usage position during use. Since the electrical components inside new energy vehicles are densely arranged, and the flat cable, as the main power supply cable, has a high current and high power during operation, the flat cable generates a large amount of heat during operation. If the heat generated by the flat cable is allowed to spread randomly during the long-term driving of new energy vehicles, it will cause the temperature of other electronic components arranged around the flat cable to continue to rise, thereby causing faults during the operation of the electronic components, and further reducing the usage safety of the flat cable. Summary of the Invention

[0004] The present invention provides an aluminum alloy flat cable for new energy vehicles, which can effectively solve the problem that the aluminum alloy flat cable is restricted by its usage position during use. Since the electrical components inside new energy vehicles are densely arranged, and the flat cable, as the main power supply cable, has a high current and high power during operation, the flat cable generates a large amount of heat during operation. If the heat generated by the flat cable is allowed to spread randomly during the long-term driving of new energy vehicles, it will cause the temperature of other electronic components arranged around the flat cable to continue to rise, thereby causing faults during the operation of the electronic components, and further reducing the usage safety of the flat cable as mentioned in the above background art.

[0005] To achieve the above object, the present invention provides the following technical solution: An aluminum alloy flat cable for new energy vehicles, including an aluminum alloy solid conductor, and a composite insulation layer is arranged outside the aluminum alloy solid conductor;

[0006] A multifunctional directional heat conduction circulation mechanism is arranged inside the composite insulation layer, and the multifunctional directional heat conduction circulation mechanism is used to isolate the temperature inside the cable and assist in dissipating the heat inside the cable during the use of the cable;

[0007] The multifunctional directional heat conduction circulation mechanism comprises an aerogel insulation layer;

[0008] The composite insulation layer is coated with an aerogel insulation layer, a limited center groove is provided inside the aerogel insulation layer, a heat-conducting silicone sheet is clamped inside the limited center groove, a center connecting sleeve is connected to the middle of the heat-conducting silicone sheet, and limited elastic lines are inserted and connected at the four corners of the center connecting sleeve;

[0009] The inner side of the central connecting sleeve is inserted with a flow guide outer tube, the inner side of the flow guide outer tube is inserted with a return flow inner tube, and the outer side of the return flow inner tube is sleeved with an internal support ring;

[0010] A connecting inner hard pipe is fixedly installed at the bottom of the side surface of the reflux inner pipe, and a connecting outer hard pipe is connected inside the guide outer pipe.

[0011] According to the above technical solution, the nominal cross-sectional area of ​​the aluminum alloy solid conductor is 30mm 2 ~500mm 2 , its cross-sectional shape is rectangular or elliptical, and the ratio of width to thickness is 4.5 to 8.5;

[0012] The aluminum alloy solid conductor has a tensile strength of ≥135 MPa, a yield strength of ≥90 MPa, a HV Vickers hardness of ≥43, an elongation at break of ≥16.5%, and a conductivity of ≥59.5% IACS;

[0013] The transverse bending radius of the aluminum alloy solid conductor satisfies 1D to 3D;

[0014] The four corners of the aluminum alloy solid conductor are arc chamfered, and the chamfer radius is 0.8 to 3.0 mm;

[0015] The composite insulation layer is made of nylon, silicone rubber, PVC, XLPE, XLPO or TPE polymer series;

[0016] When the cross-sectional shape of the aluminum alloy solid conductor is an ellipse, the two narrow sides of the ellipse conductor are semicircular transitions, and the radius thereof is 1 / 2 of the thickness value;

[0017] The aluminum alloy solid conductor and its component percentages are as follows: Si: 0.35 - 0.55, Mg: 0.40 - 0.60, Fe: 0.05 - 0.25, Cu: the content is not more than 0.01, Mn: the content is not more than 0.03, Cr: the content is not more than 0.01%, B: the content is not more than 0.01, Zn: the content is not more than 0.01, the balance is Al and unavoidable impurities, the single content of unavoidable impurities is not more than 0.03, and the total impurity content is not more than 0.10;

[0018] The aluminum alloy solid conductor further includes a terminal head, and the terminal head can be arbitrarily adjusted and designed according to the structural requirements of the in-vehicle connector and connected.

[0019] According to the above technical solution, the inner side of the aerogel thermal insulation layer is closely attached to the outer side of the aluminum alloy solid conductor and the heat-conducting silica gel sheet, and the inner side of the heat-conducting silica gel sheet is closely attached to both sides of the central connecting sleeve;

[0020] Sealing end plugs are movably clamped at both ends of the diversion outer pipe and the return inner pipe, and the inside of the diversion outer pipe and the return inner pipe are both filled with heat-conducting oil;

[0021] A communicating installation cover is arranged at the bottom of the connecting inner hard pipe and the connecting outer hard pipe. The inner cavities of the diversion outer pipe and the return inner pipe are communicated through the communicating installation cover, and the top end of the communicating installation cover is fixedly connected to the top surface of the inner cavity of the active circulation bottom box.

[0022] According to the above technical solution, a connecting rubber plug is closely sleeved on the outer side of the connecting outer hard pipe, the connecting rubber plug is bonded with an active circulation bottom box at the bottom, diversion bent plates are fixedly clamped at both ends inside the active circulation bottom box, and protective end plates are embedded and installed in the middle of both ends of the active circulation bottom box;

[0023] A mini motor is clamped at the middle of the bottom surface of the active circulation bottom box corresponding to the bottom of the connecting outer hard pipe. The mini motor is powered by an external power supply. The top end of the output shaft of the mini motor is connected to a mini infusion auger through a one-way bearing corresponding to the inside of the connecting inner hard pipe, and a driving paddle is fixedly sleeved at the bottom of the mini infusion auger corresponding to the bottom inside of the active circulation bottom box;

[0024] One end of the bottom of the composite insulation layer away from the active circulation bottom box is fixedly connected to a passive circulation bottom box through another group of connecting inner hard pipes and connecting outer hard pipes. A diversion concentric cover is fixedly connected to the bottom ends of the connecting inner hard pipe and the connecting outer hard pipe corresponding to the inside of the passive circulation bottom box. A liquid discharge side pipe is fixedly connected to one side of the diversion concentric cover corresponding to the bottom of the connecting outer hard pipe, and a return side pipe is fixedly connected to the other side of the diversion concentric cover corresponding to the bottom of the connecting inner hard pipe;

[0025] Both ends of the liquid discharge side pipe and the reflux side pipe are fixedly connected with driving square end boxes, and liquid guiding side square pipes are fixedly installed at both sides between the two driving square end boxes;

[0026] A driving rectangular piece is slidably clamped at the inner bottom of the liquid guiding side square pipe. The bottom of the driving rectangular piece is fixedly connected with a connecting crank rod. Driving counterweight blocks are fixedly connected to both ends inside the passive circulation bottom box corresponding to both ends of the connecting crank rod. Support springs are embedded in the middle of both ends of the bottom surface of the driving counterweight block.

[0027] According to the above technical solution, the diversion bent plates are symmetrically distributed about the center inside the active circulation bottom box, and the two ends inside the active circulation bottom box are interconnected. Air guide holes are evenly formed in the corresponding ends of the two protective end plates. The outer side of the driving paddle is in close sliding fit with the inner side of the diversion bent plate.

[0028] According to the above technical solution, the connecting inner hard pipe and the connecting outer hard pipe at the bottom inside the diversion concentric cover are not interconnected, and one-way valves are embedded in the middle of the outer sides of the liquid discharge side pipe and the reflux side pipe.

[0029] According to the above technical solution, the driving square end boxes are communicated through the liquid guiding side square pipe. The outer side of the driving rectangular piece is in close sliding fit with the inner wall of the driving square end box. A limiting thin frame is arranged at the inner top of the driving square end box. The outer side of the driving counterweight block is in close sliding fit with the inner wall of the passive circulation bottom box. The bottom end of the support spring is in close fit with the inner bottom surface of the passive circulation bottom box.

[0030] According to the above technical solution, an outer ring protection installation mechanism is arranged on the outer side of the composite insulation layer;

[0031] The outer ring protection installation mechanism includes an installation protection strip;

[0032] Installation protection strips are bonded to the top and bottom of the outer side of the composite insulation layer. Protection hard pieces are evenly embedded in the middle of the side surface of the installation protection strip at equal intervals. A protection side strip is fixedly connected between the side surfaces of the two installation protection strips. Extrusion arc grooves are formed at the top and bottom of the protection side strip. Central support elastic pieces are evenly inserted in the middle of the inner side of the protection side strip at equal intervals.

[0033] Elastic grooves are evenly formed at the ends of the central support elastic pieces at equal intervals. A central expansion groove is formed in the middle of one side of the central support elastic piece. A central connecting cable is inserted through the middle of the central support elastic piece. Elastic buffer air bags are inserted through the top and bottom of the protection side strip.

[0034] According to the above technical solution, the side of the protective hard sheet is flush with the side of the installation protective strip, the inner side of the protective side strip is closely attached to the outer side of the composite insulating layer, and the side of the installation protective strip and the protective side strip are connected through a card slot.

[0035] According to the above technical solution, the outer side of the central support spring sheet is closely attached to the inner side of the protective side strip, and the elastic buffer airbag is compressed after being squeezed.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows: The structure of the present invention is scientific and reasonable, and it is safe and convenient to use:

[0037] 1. A multifunctional directional heat conduction and circulation mechanism is provided. Through the mutual cooperation among the components inside the multifunctional directional heat conduction and circulation mechanism, the temperature regulation process during the use of the flat cable is optimized. The internal temperature of the flat cable is isolated and protected by the aerogel thermal insulation layer to prevent the heat generated during the use of the flat cable from spreading randomly to the surroundings of other electrical components inside the new energy vehicle. Through the circulation of the heat-conducting oil inside the diversion outer tube and the return inner tube, the heat inside the flat cable is directionally transferred, and the flat cable is cooled during the circulation of the heat-conducting oil, thereby ensuring that the internal temperature of the flat cable can be maintained within a suitable temperature range during use, effectively preventing the heat generated during the operation of the flat cable from spreading randomly and causing abnormal temperature rise of the surrounding electronic components, affecting the normal use, ensuring that the flat cable will not affect the normal use of the vehicle during use, and effectively improving the use safety of the flat cable;

[0038] Through the mutual cooperation among the components inside the active circulation bottom box and the passive circulation bottom box, the flow process of the heat-conducting oil inside the diversion outer tube and the return inner tube is optimized. Through the mutual cooperation between the mini motor and the mini infusion auger, the heat-conducting oil can be driven for active circulation, and through the mutual cooperation between the diversion bent plate and the driving paddle, the heat-conducting oil is driven to circulate by the airflow generated during the vehicle's travel. Through the mutual cooperation between the driving counterweight and the support spring, the kinetic energy of the driving counterweight rising and falling during the bumpy travel of the vehicle can be used to drive the heat-conducting oil to circulate, further optimizing the circulation mode of the heat-conducting oil inside the diversion outer tube and the return inner tube, making full use of various external conditions during the use of the flat cable, and further improving the use convenience of the flat cable;

[0039] Moreover, the aluminum alloy solid conductor is limited and clamped through the cooperation of the heat-conducting silica gel sheet and the central connecting sleeve to prevent the aluminum alloy solid conductor from shifting randomly during installation and use, and the heat on the aluminum alloy solid conductor can be conducted, so that the heat on the aluminum alloy solid conductor can be transferred to the inside of the diversion outer tube more quickly. The positions of the passive circulation bottom box and the active circulation bottom box are adjusted and installed through the length-variable connecting inner hard tube and the connecting outer hard tube, so that the active circulation bottom box can obtain sufficient air flow during use, and the passive circulation bottom box can obtain sufficient vibration during use, thereby effectively improving the convenience and stability of the flat cable in use.

[0040] 2. An outer ring protection and installation mechanism is provided. Through the mutual cooperation among the components inside the outer ring protection and installation mechanism, the installation and protection process of the flat cable is optimized. The overall outside of the flat cable is protected through the mutual cooperation between the installation protection strip and the protection side strip, and the side of the installation protection strip is locally hardened through the protection hard piece, so that the side of the protection hard piece can be extruded and strengthened during the installation of the flat cable. The overall flat cable is limited through the extrusion deformation of the protection side strip, thereby effectively improving the tightness and stability of the flat cable installation.

[0041] At the same time, the overall deformation ability of the protection side strip can be improved through the extrusion arc groove, the structural hardness inside the protection side strip is increased through the central support elastic sheet, and the inside of the protection side strip is flexibly supported through the elastic buffer airbag, further improving the installation stability and fitting tightness of the flat cable. The central support elastic sheet is limited and assisted through the mutual cooperation between the elastic groove and the central connecting cable to ensure that the central support elastic sheet can still maintain sufficient shape and elasticity during the bending process of the flat cable, further improving the installation stability and installation strength of the cable.

[0042] In summary, through the mutual cooperation among the components inside the multi-functional directional heat-conducting circulation mechanism and the outer ring protection and installation mechanism, the installation process and use process of the flat cable are optimized. Through the mutual cooperation among the components outside the composite insulation layer, the flat cable can maintain sufficient contact with the installation channel during the installation process, thereby effectively improving the installation stability of the flat cable. At the same time, through the transfer and adjustment of the internal temperature during the use process of the flat cable, it is ensured that the heat generated during the use process of the flat cable will not diffuse randomly and affect the normal use of the surrounding electronic components, thereby effectively improving the use safety of the cable. At the same time, through the mutual cooperation among the components inside the active circulation bottom box and the passive circulation bottom box, the heat-conducting process and heat-dissipating process of the flat cable can make full use of the air flow and vibration in the working environment, further improving the convenience of the flat cable in use. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings are used to provide a further understanding of the present invention and form a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention.

[0044] In the accompanying drawings:

[0045] Figure 1 is a schematic structural diagram of the present invention;

[0046] Figure 2 is a schematic structural diagram of the end face of the present invention;

[0047] Figure 3 is a schematic structural diagram of the multifunctional directional heat conduction circulation mechanism of the present invention;

[0048] Figure 4 is a schematic structural diagram of the installation of the heat-conducting silica gel sheet of the present invention;

[0049] Figure 5 is a schematic structural diagram of the installation of the passive circulation bottom box of the present invention;

[0050] Figure 6 is a schematic structural diagram of the installation of the connecting inner hard pipe of the present invention;

[0051] Figure 7 is a schematic structural diagram of the installation of the mini motor of the present invention;

[0052] Figure 8 is a schematic structural diagram of the installation of the liquid guide side pipe of the present invention;

[0053] Figure 9 is a schematic structural diagram of the installation of the driving counterweight of the present invention;

[0054] Figure 10 is a schematic structural diagram of the outer ring protection installation mechanism of the present invention;

[0055] Figure 11 is a schematic structural diagram of the installation of the installation protection strip of the present invention;

[0056] Figure 12 is a schematic structural diagram of the installation of the elastic buffer airbag of the present invention;

[0057] Reference numerals in the drawings: 1. Aluminum alloy solid conductor; 2. Composite insulation layer;

[0058] 3. Multi-functional directional heat conduction circulation mechanism; 301. Aerogel thermal insulation layer; 302. Limit center groove; 303. Thermal conductive silica gel sheet; 304. Center connecting sleeve; 305. Limit elastic wire; 306. Diversion outer tube; 307. Return inner tube; 308. Internal support ring; 309. Sealing end plug; 310. Connecting inner hard tube; 311. Connecting outer hard tube; 312. Connecting rubber plug; 313. Active circulation bottom box; 314. Diversion bent plate; 315. Protection end plate; 316. Connecting and installing cover; 317. Miniature motor; 318. Miniature infusion auger; 319. Driving paddle; 320. Passive circulation bottom box; 321. Diversion concentric cover; 322. Drainage side tube; 323. Return side tube; 324. Driving square end box; 325. Liquid guiding side square tube; 326. Driving rectangular sheet; 327. Connecting crank lever; 328. Driving counterweight; 329. Support spring;

[0059] 4. Outer ring protection installation mechanism; 401. Installation protection strip; 402. Protection hard sheet; 403. Protection side strip; 404. Extrusion arc groove; 405. Center support elastic sheet; 406. Elastic groove; 407. Center expansion groove; 408. Center connecting cable; 409. Elastic buffer airbag. Specific implementation mode

[0060] The following is a description of the preferred embodiments of the present invention with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only for the purpose of illustrating and explaining the present invention, and are not used to limit the present invention.

[0061] Embodiment: As Figures 1-12 shown, the present invention provides a technical solution, an aluminum alloy flat cable for new energy vehicles, including an aluminum alloy solid conductor 1, a composite insulation layer 2 is arranged outside the aluminum alloy solid conductor 1, and the nominal cross-sectional area of the aluminum alloy solid conductor 1 is 30mm 2 ~500mm 2 , and its cross-sectional shape is rectangular or elliptical, and the ratio of width to thickness is 4.5~8.5;

[0062] The tensile strength of the aluminum alloy solid conductor 1 ≥ 135MPa, the yield strength ≥ 90MPa, the HV Vickers hardness ≥ 43, the elongation at break ≥ 16.5%, and the conductivity ≥ 59.5% IACS;

[0063] The lateral bending radius of the aluminum alloy solid conductor 1 satisfies 1D~3D;

[0064] The four corners of the aluminum alloy solid conductor 1 are chamfered with an arc transition, and the chamfering radius is 0.8~3.0mm;

[0065] The composite insulation layer 2 adopts nylon material, silicone rubber, PVC, XLPE, XLPO or TPE polymer series;

[0066] When the cross-sectional shape of the aluminum alloy solid conductor 1 is an ellipse, the two narrow sides of the ellipse conductor are semicircular transitions, and the radius thereof is 1 / 2 of the thickness value;

[0067] Aluminum alloy solid conductor 1 and the percentage of each component are: Si: 0.35-0.55, Mg: 0.40-0.60, Fe: 0.05-0.25, Cu: content not more than 0.01, Mn: content not more than 0.03, Cr: content not more than 0.01%, B: content not more than 0.01, Zn: content not more than 0.01, the balance is Al and inevitable impurities, the content of each inevitable impurity is not more than 0.03, and the total impurity content is not more than 0.10;

[0068] The aluminum alloy solid conductor 1 also includes a terminal, which can be arbitrarily adjusted and designed according to the structural requirements of the in-vehicle connector and connected;

[0069] A multifunctional directional heat transfer circulation mechanism 3 is arranged inside the composite insulation layer 2, and the multifunctional directional heat transfer circulation mechanism 3 is used to isolate the temperature inside the cable and assist in extracting the heat inside the cable during the use of the cable;

[0070] The multifunctional directional heat conduction circulation mechanism 3 comprises an aerogel insulation layer 301, a limiting center groove 302, a heat-conducting silicone sheet 303, a center connecting sleeve 304, a limiting elastic line 305, a flow guide outer tube 306, a reflux inner tube 307, an internal support ring 308, a sealing end plug 309, a connecting inner hard tube 310, a connecting outer hard tube 311, a connecting rubber plug 312, an active circulation bottom box 313, a flow guide curved plate 314, a protective end plate 315, a connecting installation cover 316, a mini motor 317, a mini infusion auger 318, a driving blade 319, a passive circulation bottom box 320, a flow guide concentric cover 321, a discharge side tube 322, a reflux side tube 323, a driving square end box 324, a flow guide side square tube 325, a driving rectangular sheet 326, a connecting turning rod 327, a driving counterweight block 328 and a supporting spring 329;

[0071] Inside the composite insulation layer 2, a aerogel thermal insulation layer 301 is tightly coated at the position corresponding to the two aluminum alloy solid conductors 1. At the middle of the inner top surface and the bottom surface of the aerogel thermal insulation layer 301, limiting center grooves 302 are opened. At the positions corresponding to the top surface and the bottom surface of the aluminum alloy solid conductor 1 inside the limiting center grooves 302, heat-conducting silica gel sheets 303 are evenly and equidistantly clamped. At the middle positions of two adjacent heat-conducting silica gel sheets 303, a center connecting sleeve 304 is fixedly connected. At the four corners of the center connecting sleeve 304, limiting elastic wires 305 are inserted and connected. The four corners of the aluminum alloy solid conductor 1 are transitioned with arc chamfers, and the chamfer radius is 2 mm. The composite insulation layer 2 is made of silicone rubber, meeting the requirements of the service environment temperature of -40 to +70 °C and the long-term operating temperature of 125 °C. The inner side of the aerogel thermal insulation layer 301 is closely attached to the outer sides of the aluminum alloy solid conductor 1 and the heat-conducting silica gel sheet 303, and the inner side of the heat-conducting silica gel sheet 303 is closely attached to both sides of the center connecting sleeve 304;

[0072] Inside the center connecting sleeve 304, a diversion outer tube 306 is closely inserted. Inside the diversion outer tube 306, a reflux inner tube 307 is inserted. On the outer side of the reflux inner tube 307, internal support rings 308 are evenly and equidistantly sleeved. At the ends of the diversion outer tube 306 and the reflux inner tube 307, sealing end plugs 309 are movably clamped;

[0073] At the bottom of the side surface of the reflux inner tube 307, a connecting inner hard tube 310 is fixedly installed. At the position corresponding to the outer side of the connecting inner hard tube 310 inside the diversion outer tube 306, a connecting outer hard tube 311 is fixedly connected. On the outer side of the connecting outer hard tube 311, a connecting rubber plug 312 is closely sleeved. At the bottom of the connecting rubber plug 312, an active circulation bottom box 313 is bonded. At both ends inside the active circulation bottom box 313, diversion bending plates 314 are fixedly clamped. At the middle of both ends of the active circulation bottom box 313, protective end plates 315 are embedded and installed. At the bottom of the connecting inner hard tube 310 and the connecting outer hard tube 311, a communication installation cover 316 is provided. Heat-conducting oil is filled inside both the diversion outer tube 306 and the reflux inner tube 307. The inner cavities of the diversion outer tube 306 and the reflux inner tube 307 are communicated through the communication installation cover 316, and a fixed connection is made between the top end of the communication installation cover 316 and the inner top surface of the active circulation bottom box 313;

[0074] In the middle of the bottom surface of the active circulation bottom box 313, a mini motor 317 is clamped at a position corresponding to the bottom of the outer hard pipe 311. The mini motor 317 is powered by an external power supply. At the top of the output shaft of the mini motor 317, a mini infusion auger 318 is connected through a one-way bearing at a position corresponding to the inside of the inner hard pipe 310. At the bottom of the mini infusion auger 318, a driving paddle 319 is fixedly sleeved at a position corresponding to the inner bottom of the active circulation bottom box 313. The diversion curved plates 314 are symmetrically distributed around the center inside the active circulation bottom box 313, and the two ends inside the active circulation bottom box 313 are interconnected. Guide air holes are evenly formed at corresponding ends of the two protective end plates 315. The outer side of the driving paddle 319 is in close sliding fit with the inner side of the diversion curved plate 314;

[0075] At one end of the bottom of the composite insulation layer 2 away from the active circulation bottom box 313, a passive circulation bottom box 320 is fixedly connected by another group of connecting inner hard pipes 310 and connecting outer hard pipes 311. At a position corresponding to the inside of the passive circulation bottom box 320 at the bottom ends of the connecting inner hard pipe 310 and the connecting outer hard pipe 311, a diversion concentric cover 321 is fixedly connected. At a position corresponding to the bottom of the outer hard pipe 311 on one side of the diversion concentric cover 321, a liquid discharge side pipe 322 is fixedly connected. At a position corresponding to the bottom of the inner hard pipe 310 on the other side of the diversion concentric cover 321, a return flow side pipe 323 is fixedly connected. The bottoms of the connecting inner hard pipe 310 and the connecting outer hard pipe 311 inside the diversion concentric cover 321 are not interconnected. Check valves are embedded and installed in the middle of the outer sides of the liquid discharge side pipe 322 and the return flow side pipe 323;

[0076] Both ends of the liquid discharge side pipe 322 and the return flow side pipe 323 are fixedly connected with driving square end boxes 324. A liquid guide side square pipe 325 is fixedly installed at both sides between the two driving square end boxes 324;

[0077] A driving rectangular piece 326 is slidably clamped at the inner bottom of the liquid guiding side pipe 325. A connecting crank lever 327 is fixedly connected to the bottom of the driving rectangular piece 326. Driving counterweight blocks 328 are fixedly connected to the ends of the connecting crank lever 327 corresponding to both ends inside the passive circulation bottom box 320. Support springs 329 are embedded in the middle of both ends of the bottom surface of each driving counterweight block 328. The driving square end boxes 324 are communicated with each other through the liquid guiding side pipe 325. The outer side of the driving rectangular piece 326 is in close sliding fit with the inner wall of the driving square end box 324. A limiting thin frame is arranged at the inner top of the driving square end box 324. The outer side surface of the driving counterweight block 328 is in close sliding fit with the inner wall of the passive circulation bottom box 320. The bottom end of the support spring 329 is in close fit with the inner bottom surface of the passive circulation bottom box 320. Through the mutual cooperation among the components inside the multi-functional directional heat conduction circulation mechanism 3, the temperature adjustment process during the use of the flat cable is optimized. The temperature inside the flat cable is isolated and protected by the aerogel heat insulation layer 301 to prevent the heat generated during the use of the flat cable from randomly diffusing to the surroundings of other electrical components inside the new energy vehicle. Then, the heat inside the flat cable is directionally transferred through the circulation of the heat-conducting oil inside the diversion outer pipe 306 and the return inner pipe 307, and the flat cable is cooled during the circulation of the heat-conducting oil, thereby ensuring that the temperature inside the flat cable can be maintained within a suitable range during use and effectively preventing the heat generated during the operation of the flat cable from randomly diffusing and causing abnormal temperature rise of the surrounding electronic components, which affects the normal use, ensuring that the flat cable does not affect the normal use of the vehicle during use, and effectively improving the use safety of the flat cable;

[0078] Through the mutual cooperation among the components inside the active circulation bottom box 313 and the passive circulation bottom box 320, the flow process of the heat-conducting oil inside the diversion outer pipe 306 and the return inner pipe 307 is optimized. Through the mutual cooperation between the mini motor 317 and the mini infusion auger 318, the heat-conducting oil can be driven to circulate actively. Through the mutual cooperation between the diversion bent plate 314 and the driving paddle 319, the airflow generated during the driving of the vehicle is used to drive the heat-conducting oil to circulate. Through the mutual cooperation between the driving counterweight block 328 and the support spring 329, the kinetic energy of the lifting and falling of the driving counterweight block 328 during the bumpy driving of the vehicle can be used to drive the heat-conducting oil to circulate, further optimizing the circulation mode of the heat-conducting oil inside the diversion outer pipe 306 and the return inner pipe 307, making full use of various external conditions during the use of the flat cable, and further improving the use convenience of the flat cable;

[0079] Moreover, the aluminum alloy solid conductor 1 is limited and clamped through the cooperation of the heat-conducting silica gel sheet 303 and the central connecting sleeve 304 to prevent the aluminum alloy solid conductor 1 from shifting randomly during installation and use, and the heat on the aluminum alloy solid conductor 1 can be conducted, so that the heat on the aluminum alloy solid conductor 1 can be transferred to the inside of the diversion outer tube 306 more quickly. The positions of the passive circulation bottom box 320 and the active circulation bottom box 313 are adjusted and installed through the length-variable connecting inner hard tube 310 and the connecting outer hard tube 311, so that the active circulation bottom box 313 can obtain sufficient air flow during use, and the passive circulation bottom box 320 can obtain sufficient vibration during use, thereby effectively improving the convenience and stability of the flat cable in use;

[0080] An outer ring protection and installation mechanism 4 is arranged on the outside of the composite insulation layer 2;

[0081] The outer ring protection and installation mechanism 4 includes an installation protection strip 401, a protection hard sheet 402, a protection side strip 403, an extrusion arc groove 404, a central support elastic sheet 405, an elastic groove 406, a central expansion groove 407, a central connecting cable 408 and an elastic buffer airbag 409;

[0082] Installation protection strips 401 are bonded to both the top and bottom of the outside of the composite insulation layer 2. Protection hard sheets 402 are evenly embedded in the middle of the side of the installation protection strip 401 at equal intervals. The side of the protection hard sheet 402 is flush with the side of the installation protection strip 401. The inner side of the protection side strip 403 is closely attached to the outside of the composite insulation layer 2. The side of the installation protection strip 401 and the protection side strip 403 are connected through a card slot;

[0083] A protective side strip 403 is fixedly connected between the sides of two installation protective strips 401. Extrusion arc grooves 404 are provided at both the top and bottom of the protective side strip 403. Center support elastic sheets 405 are evenly inserted and installed at equal intervals in the middle of the inner side of the protective side strip 403. Elastic grooves 406 are evenly opened at equal intervals at the ends of the center support elastic sheets 405. A center expansion groove 407 is opened in the middle of one side of the center support elastic sheet 405. A center connecting cable 408 is inserted and installed in the middle of the center support elastic sheet 405. Elastic buffer air bags 409 are inserted and installed at both the top and bottom of the protective side strip 403. The outer side of the center support elastic sheet 405 is closely attached to the inner side of the protective side strip 403. After being squeezed, the elastic buffer air bag 409 is compressed. Through the mutual cooperation between the components inside the outer ring protection installation mechanism 4, the installation protection process of the flat cable is optimized. The outer side of the flat cable is protected as a whole through the mutual cooperation between the installation protective strip 401 and the protective side strip 403, and the side of the installation protective strip 401 is locally hardened through the protective hard sheet 402, so that the side of the protective hard sheet 402 can be squeezed and strengthened when the flat cable is installed. Then, the overall flat cable is limited by the extrusion deformation of the protective side strip 403, thereby effectively improving the tightness and stability of the flat cable installation;

[0084] At the same time, the overall deformation ability of the protective side strip 403 can be improved through the extrusion arc groove 404. Then, the internal structural hardness of the protective side strip 403 is improved through the center support elastic sheet 405, and the inner part of the protective side strip 403 is flexibly supported through the elastic buffer air bag 409, further improving the installation stability and fitting tightness of the flat cable. The center support elastic sheet 405 is limited and assisted through the mutual cooperation between the elastic groove 406 and the center connecting cable 408 to ensure that the center support elastic sheet 405 can still maintain sufficient shape and elasticity during the bending process of the flat cable, further improving the installation stability and installation strength of the cable.

[0085] The working principle and usage process of the present invention: In the actual application process of the present invention, during the use of the aluminum alloy flat cable, the aluminum alloy solid conductor 1 needs to be first connected to a suitable position for power supply, and the outer side of the aluminum alloy solid conductor 1 is protected through the composite insulation layer 2. When it is necessary to direct the heat generated during the long-term operation of the flat cable, the composite insulation layer 2 is isolated through the aerogel thermal insulation layer 301 to prevent the heat generated during the use of the flat cable from diffusing out randomly;

[0086] Then, the heat-conducting silica gel sheet 303 and the central connecting sleeve 304 are evenly installed inside the composite insulating layer 2 through the limiting central groove 302. The central connecting sleeves 304 are flexibly limited by the limiting elastic wires 305, and the two aluminum alloy solid conductors 1 are limited by the cooperation between the heat-conducting silica gel sheet 303 and the central connecting sleeve 304 to prevent the aluminum alloy solid conductors 1 from shifting during the use of the flat cable.

[0087] When it is necessary to continue to direct the heat inside the flat cable, the heat-conducting oil inside the diversion outer tube 306 absorbs the heat generated by the aluminum alloy solid conductor 1. When it is necessary to assist the circulation of the heat-conducting oil inside the diversion outer tube 306 and the return inner tube 307, the mini motor 317 is started to drive the mini infusion auger 318 to rotate continuously. During the rotation of the mini infusion auger 318, the heat-conducting oil inside the connected installation cover 316 continuously enters the connecting inner hard tube 310, and a continuous negative pressure is generated inside the connected installation cover 316, so that the heat-conducting oil inside the diversion outer tube 306 can continuously flow into the connected installation cover 316 through the connecting outer hard tube 311. Thus, the local circulation of the heat-conducting oil inside the diversion outer tube 306 and the return inner tube 307 is realized, and the heat generated by the aluminum alloy solid conductor 1 is carried away from the inside of the flat cable during the circulation of the heat-conducting oil.

[0088] When the high-temperature heat-conducting oil circulates through the inside of the connected installation cover 316, the airflow generated during the driving of the new energy vehicle can pass through the holes in the protective end plate 315 and enter the active circulation bottom box 313. The airflow entering the active circulation bottom box 313 is directionally guided by the diversion bent plate 314. The continuously flowing airflow drives the driving paddle 319 to rotate continuously, and during the rotation of the driving paddle 319, it assists the mini infusion auger 318 to rotate. At the same time, the continuously flowing airflow inside the active circulation bottom box 313 can also assist the heat-conducting oil inside the connected installation cover 316 to dissipate heat.

[0089] When the new energy vehicle is running at a low speed, the temperature inside the flat cable is relatively low, and passive heat dissipation of the flat cable is required. The inertial force generated during the bumpy driving of the vehicle is used to assist in driving the counterweight 328 to overcome the supporting elastic force of the supporting spring 329 for periodic lifting. During the lifting and lowering of the counterweight 328, the driving rectangular piece 326 and the connecting crank 327 are driven to lift and lower synchronously. When the driving rectangular piece 326 descends inside the driving square end box 324, a negative pressure will be generated inside the driving square end box 324. The heat-conducting oil inside the diversion outer tube 306 is pumped into the driving square end box 324 through the liquid discharge side tube 322 in cooperation with the diversion concentric cover 321, and the heat-conducting oil inside the two driving square end boxes 324 is connected and flows through the liquid guide side square tube 325. When the driving rectangular piece 326 rises, a pressure can be generated inside the driving square end box 324, so that the heat-conducting oil inside the driving square end box 324 can introduce the heat-conducting oil into the connecting inner hard tube 310 through the cooperation of the diversion concentric cover 321 and the return side tube 323;

[0090] When it is necessary to enhance the heat dissipation efficiency inside the flat cable, the connecting rubber plug 312 can be removed, and then the ends of the diversion outer tube 306 and the return inner tube 307 are respectively connected to the inlet and outlet ends of an external radiator to enhance the heat dissipation efficiency during the heat-conducting oil circulation process. At the same time, by changing the lengths of the connecting inner hard tube 310 and the connecting outer hard tube 311, the positions of the active circulation bottom box 313 and the passive circulation bottom box 320 are changed and adjusted to ensure that sufficient air flow can enter the active circulation bottom box 313 and ensure that the passive circulation bottom box 320 can vibrate sufficiently;

[0091] When auxiliary installation of the flat cable is required, affected by the shape of the flat cable, the flat cable often gets stuck in the plate groove at the bottom of the vehicle during installation. When the flat cable needs to be snapped into the groove, the outer side of the flat cable is protected by installing the protective strip 401 and the protective side strip 403 to prevent damage to the outer skin of the flat cable during installation, which affects the normal protection of the outer side of the flat cable. The side of the installation protective strip 401 is rigidly protected by the protective hard piece 402, thereby effectively improving the mechanical strength of the flat cable;

[0092] When the flat cable needs to be snapped into the groove, the inside of the protective side strip 403 is mechanically elastically supported by the central support elastic piece 405, and the elastic groove 406 assists the central support elastic piece 405 to bend and deform. Then, the central expansion groove 407 assists the central support elastic piece 405 to deform, and the central connecting cable 408 assists in connecting between the central support elastic pieces 405. The elastic deformation of the elastic buffer airbag 409 makes the outer side of the protective side strip 403 fit more closely with the inner wall of the groove, so as to achieve the tight installation of the flat cable.

[0093] Finally, it should be noted that the above are only preferred examples of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An aluminum alloy flat cable for new energy vehicles, comprising an aluminum alloy solid conductor (1), characterized in that: A composite insulating layer (2) is provided on the outer side of the aluminum alloy solid conductor (1); A multifunctional directional heat conduction circulation mechanism (3) is arranged inside the composite insulation layer (2), and the multifunctional directional heat conduction circulation mechanism (3) is used to isolate the temperature inside the cable and to assist in dissipating the heat inside the cable during the use of the cable; The multifunctional directional heat conduction circulation mechanism (3) comprises an aerogel heat insulation layer (301); The composite insulation layer (2) is coated with an aerogel thermal insulation layer (301), a limited central groove (302) is provided on the inner side of the aerogel thermal insulation layer (301), a thermal conductive silicone sheet (303) is clamped on the inner side of the limited central groove (302), a central connecting sleeve (304) is connected to the middle of the thermal conductive silicone sheet (303), and limited elastic lines (305) are inserted and connected at the four corners of the central connecting sleeve (304); An outer flow guide tube (306) is inserted into the inner side of the central connecting sleeve (304), an inner return tube (307) is inserted into the inner side of the outer flow guide tube (306), and an inner support ring (308) is sleeved on the outer side of the inner return tube (307); A connecting inner hard pipe (310) is fixedly mounted on the bottom of the side of the return inner pipe (307), and a connecting outer hard pipe (311) is connected inside the flow guiding outer pipe (306).

2. The aluminum alloy flat cable for new energy vehicles according to claim 1, wherein The nominal cross-sectional area of the aluminum alloy solid conductor (1) is 30 mm 2 ~500 mm 2 , and its cross-sectional shape is rectangular or elliptical, and the ratio of width to thickness is 4.5 to 8.5; The aluminum alloy solid conductor (1) has a tensile strength of ≥135 MPa, a yield strength of ≥90 MPa, a HV Vickers hardness of ≥43, an elongation at break of ≥16.5%, and a conductivity of ≥59.5% IACS; The aluminum alloy solid conductor (1) has a transverse bending radius that satisfies 1D to 3D; The four corners of the aluminum alloy solid conductor (1) are arc chamfered, and the chamfer radius is 0.8 to 3.0 mm; The composite insulating layer (2) is made of nylon, silicone rubber, PVC, XLPE, XLPO or TPE polymer series; When the cross-sectional shape of the aluminum alloy solid conductor (1) is an ellipse, the two narrow sides of the ellipse conductor are semicircular transitions, and the radius thereof is 1 / 2 of the thickness value; The aluminum alloy solid conductor (1) and the percentage of each component are: Si: 0.35-0.55, Mg: 0.40~0.60, Fe: 0.05~0.25, Cu: content not more than 0.01, Mn: content not more than 0.03, Cr: content not more than 0.01%, B: content not more than 0.01, Zn: content not more than 0.01, the balance is Al and unavoidable impurities, the content of each unavoidable impurity is not more than 0.03, and the total impurity content is not more than 0.10; The aluminum alloy solid conductor (1) also includes an end head, and the end head can be arbitrarily adjusted in design and connected according to the structural requirements of the in-vehicle connector.

3. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, The inner side of the aerogel insulation layer (301) is tightly fitted to the aluminum alloy solid conductor (1) and the outer side of the thermally conductive silicone sheet (303), and the inner side of the thermally conductive silicone sheet (303) is tightly fitted to both sides of the central connecting sleeve (304); Sealing end plugs (309) are movably clamped at the ends of the diversion outer tube (306) and the reflux inner tube (307), and heat-conducting oil is filled inside the diversion outer tube (306) and the reflux inner tube (307); A communicating installation cover (316) is arranged at the bottom of the connecting inner hard tube (310) and the connecting outer hard tube (311). The inner cavities of the diversion outer tube (306) and the reflux inner tube (307) are communicated through the communicating installation cover (316), and the top of the communicating installation cover (316) is fixedly connected to the top surface of the inner cavity of the active circulation bottom box (313).

4. The aluminum alloy flat cable for new energy vehicles according to claim 1, wherein, A connecting rubber plug (312) is closely sleeved outside the connecting outer hard tube (311). The connecting rubber plug (312) is adhesively bonded to the active circulation bottom box (313) at the bottom. Flow guiding bent plates (314) are fixedly clamped at both ends inside the active circulation bottom box (313), and protective end plates (315) are embedded and installed in the middle of both ends of the active circulation bottom box (313); A mini motor (317) is clamped at the middle of the bottom surface of the active circulation bottom box (313) corresponding to the bottom of the connecting outer hard tube (311). The mini motor (317) is powered by an external power source. The top of the output shaft of the mini motor (317) is connected to a mini infusion auger (318) through a one-way bearing corresponding to the inside of the connecting inner hard tube (310). A driving paddle (319) is fixedly sleeved at the bottom of the mini infusion auger (318) corresponding to the bottom inside of the active circulation bottom box (313); One end of the bottom of the composite insulating layer (2) far away from the active circulation bottom box (313) is fixedly connected to a passive circulation bottom box (320) through another group of connecting inner hard tubes (310) and connecting outer hard tubes (311). The bottom ends of the connecting inner hard tube (310) and the connecting outer hard tube (311) are fixedly connected to a flow guiding concentric cover (321) corresponding to the inside of the passive circulation bottom box (320). A liquid discharge side tube (322) is fixedly connected to one side of the flow guiding concentric cover (321) corresponding to the bottom of the connecting outer hard tube (311), and a reflux side tube (323) is fixedly connected to the other side of the flow guiding concentric cover (321) corresponding to the bottom of the connecting inner hard tube (310); Liquid discharge side tubes (322) and reflux side tubes (323) are fixedly connected to the ends of both. Driving square end boxes (324) are fixedly installed at both sides between the two driving square end boxes (324); A driving rectangular piece (326) is slidably clamped at the bottom inside the liquid guiding side square tube (325). A connecting crank rod (327) is fixedly connected to the bottom of the driving rectangular piece (326). Driving counterweight blocks (328) are fixedly connected to both ends of the connecting crank rod (327) corresponding to both ends inside the passive circulation bottom box (320). Support springs (329) are embedded and installed in the middle of both ends of the bottom surface of the driving counterweight blocks (328).

5. The aluminum alloy flat cable for new energy vehicles according to claim 4, characterized in that, The diversion bent plates (314) are symmetrically distributed about the center inside the active circulation bottom box (313), and the two ends inside the active circulation bottom box (313) are interconnected. Air guide holes are evenly formed in the corresponding ends of the two protection end plates (315). The outer side of the driving paddle (319) is in close sliding fit with the inner side of the diversion bent plate (314).

6. The aluminum alloy flat cable for new energy vehicle according to claim 4, wherein The bottom parts of the connecting inner hard pipe (310) and the connecting outer hard pipe (311) inside the diversion concentric cover (321) are not interconnected. Check valves are embedded in the middle parts of the outer sides of the liquid discharge side pipe (322) and the reflux side pipe (323).

7. A flat aluminum alloy cable for new energy vehicles according to claim 4, characterized in that The driving square end boxes (324) are connected through the liquid guide side square pipes (325). The outer side of the driving rectangular sheet (326) is in close sliding fit with the inner wall of the driving square end box (324). A limiting thin frame is arranged at the inner top of the driving square end box (324). The outer side of the driving counterweight (328) is in close sliding fit with the inner wall of the passive circulation bottom box (320). The bottom end of the support spring (329) is in close fit with the inner bottom surface of the passive circulation bottom box (320).

8. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, An outer ring protection installation mechanism (4) is arranged on the outer side of the composite insulation layer (2); The outer ring protection installation mechanism (4) includes an installation protection strip (401); Installation protection strips (401) are bonded to the top and bottom of the outer side of the composite insulation layer (2). Protection hard pieces (402) are evenly embedded in the middle of the side surface of the installation protection strip (401) at equal intervals. A protection side strip (403) is fixedly connected between the side surfaces of the two installation protection strips (401). Extrusion arc grooves (404) are formed at the top and bottom of the protection side strip (403). Center support elastic pieces (405) are evenly inserted in the middle of the inner side of the protection side strip (403) at equal intervals; Elastic grooves (406) are evenly formed at the ends of the center support elastic piece (405). A center expansion groove (407) is formed in the middle of one side of the center support elastic piece (405). A center connecting cable (408) is inserted through the middle of the center support elastic piece (405). Elastic buffer air bags (409) are inserted through the top and bottom of the protection side strip (403).

9. The aluminum alloy flat cable for new energy vehicles according to claim 8, characterized in that The side surface of the protection hard piece (402) is flush with the side surface of the installation protection strip (401). The inner side of the protection side strip (403) is in close fit with the outer side of the composite insulation layer (2). The side surface of the installation protection strip (401) and the protection side strip (403) are connected through a card slot.

10. The aluminum alloy flat cable for new energy vehicle according to claim 8, characterized in that, The outer side of the center support elastic piece (405) is in close fit with the inner side of the protection side strip (403). The elastic buffer air bag (409) is compressed after being squeezed.

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