A composite cable for new energy vehicles

Abstract

The present invention relates to the field of cable technology, specifically a composite cable for new energy vehicles. It solves the problem that when existing cables are used in new energy vehicles, the surface of the cables is easily damaged in a complex environment, which in turn affects the driving safety of new energy vehicles and is inconvenient to arbitrarily bend and arrange the cables. The cable comprises an outer protective component and a wear monitoring component, and the wear monitoring component is installed on the inner side of the outer protective component; the outer protective component comprises a filling layer, the outer surface of the filling layer is provided with a plurality of annular arc grooves, the inner side of the annular arc groove is provided with an arc-shaped mounting ring, the interior of the arc-shaped mounting ring is provided with a plurality of annular wires, and the outer side of the filling layer is provided with a plurality of positioning clamps. The present invention can effectively meet the requirements for stable arrangement of cables in the car through segmented bending and fixing, and at the same time detect and locate the wear of the cables, so as to facilitate the timely replacement of damaged cables.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, and in particular to a composite cable for new energy vehicles. Background Art

[0002] New energy vehicle cables are multi-core cables with a variety of specifications and performance characteristics. They are designed to meet the complex electrical system requirements of new energy vehicles. These cables may have different specifications and performance characteristics depending on the vehicle design and electrical system requirements. New energy vehicle cables must have multiple properties such as high voltage resistance, high temperature resistance, electromagnetic interference protection, high flexibility, wear resistance and oil resistance. These characteristics jointly ensure the reliability and safety of cables used in new energy vehicles.

[0003] When existing cables are used in new energy vehicles, the surface of the cables is easily damaged in a complex environment, which in turn affects the driving safety of new energy vehicles, and it is not convenient to arbitrarily bend and arrange the cables; therefore, it does not meet existing needs. In this regard, we propose a composite cable for new energy vehicles. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite cable for new energy vehicles to solve the problem raised in the above background technology that when existing cables are used in new energy vehicles, the surface of the cables are easily damaged in a complex environment, thereby affecting the driving safety of new energy vehicles, and it is inconvenient to arbitrarily bend and arrange the cables.

[0005] To achieve the above-mentioned object, the present invention provides the following technical solution: a composite cable for new energy vehicles, comprising an outer protective component and a wear monitoring component, wherein the wear monitoring component is installed on the inner side of the outer protective component;

[0006] The outer protective component includes a filling layer, the outer surface of the filling layer is provided with a plurality of annular arc grooves, the inner side of the annular arc groove is provided with an arc-shaped mounting ring, the interior of the arc-shaped mounting ring is provided with a plurality of annular wires, the outer side of the filling layer is provided with a plurality of positioning clamps, the outer side of one of the positioning clamps is provided with a cable connection seat, both ends of the cable connection seat are provided with limit clamping strips, the interior of the filling layer is provided with a plurality of corrugated support rings, and both sides of each corrugated support ring are provided with elastic filling rings;

[0007] The wear monitoring assembly includes a second metal layer, a first insulating shielding layer is installed on the outer side of the second metal layer, a first metal layer is installed on the outer side of the first insulating shielding layer, and a spiral braided layer is installed on the outer side of the first metal layer;

[0008] The first metal layer and the second metal layer are electrically connected. The first metal layer and the second metal layer are both bonded and fixed to the first insulating shielding layer. The spiral braided layer is formed by braiding a plurality of spiral anti-cut strips.

[0009] Preferably, an inner layer protection component is installed on the inner side of the wear monitoring component, a plurality of battery cells are installed on the inner side of the inner layer protection component, a central support component is installed between the plurality of battery cells, and the outer layer protection component also includes a flame retardant layer fixedly connected to the filling layer, the flame retardant layer is installed between the filling layer and a plurality of positioning clips, and the plurality of arc-shaped mounting rings are all arranged between the flame retardant layer and the filling layer.

[0010] Preferably, the inner protective component includes a thermally conductive filling body, a plurality of insulating pressure rings are installed on the outside of the thermally conductive filling body, a plurality of sheet thermistors are installed on the outside of each insulating pressure ring, and a plurality of elastic separation strips are installed inside the thermally conductive filling body.

[0011] Preferably, the battery cell unit includes a second insulating shielding layer, the outer surface of the second insulating shielding layer is provided with a plurality of reinforcing ridges, the inner side of the second insulating shielding layer is installed with an anti-wear layer, and the battery cell body is installed on the inner side of the anti-wear layer.

[0012] Preferably, the central support assembly includes a connecting layer, the outer surface of the connecting layer is provided with spiral support bars, and the inner side of the connecting layer is installed with a central metal bar.

[0013] Preferably, the filling layer and the flame retardant layer are bonded and fixed, the arc-shaped mounting ring is arranged between the flame retardant layer and the filling layer, and the filling layer and the annular wire are fixedly connected via the arc-shaped mounting ring.

[0014] Preferably, the positioning clamp is bonded and fixed to the flame retardant layer, and a plurality of positioning heads arranged in a circle are provided on the outer side of the positioning clamp. The positioning clamp and the cable connection seat are clamped and installed through the plurality of positioning heads, and both ends of the cable connection seat and the limit strip are clamped and installed.

[0015] Preferably, the thermally conductive filling body is fixedly connected to the sheet thermistor through an insulating pressure ring, the thermally conductive filling body is fixedly connected to the filling layer through a wear monitoring component, multiple sheet thermistors are arranged circumferentially relative to the insulating pressure ring, and multiple insulating pressure rings are arranged linearly along the axis of the thermally conductive filling body.

[0016] Preferably, the thermally conductive filling body is fixedly connected to a plurality of elastic separators, and the plurality of elastic separators and the plurality of second insulating shielding layers are arranged circumferentially relative to the axis of the thermally conductive filling body. An elastic separator is provided between two adjacent second insulating shielding layers, and the elastic separator and the second insulating shielding layer are both coaxial with the thermally conductive filling body.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. The present invention can insulate and separate the first metal layer and the second metal layer through the first insulating shielding layer, maintaining the first metal layer and the second metal layer to monitor the wear of the cable. The spiral braided layer and multiple corrugated support rings can effectively improve the automatic recovery rate of the cable after being compressed. When the flame retardant layer, the filling layer and the spiral braided layer are subjected to external wear and damage, the electrical connection between the first metal layer and the second metal layer is synchronously stopped, thereby accurately and in real time determining the degree of damage to the cable and the location of the damage, avoiding the use risk caused by exposed battery cells.

[0019] 2. The present invention can perform fixed-point bending through the linearly arranged annular arc grooves and arc-shaped mounting rings on the surface of the cable, which is convenient for the arbitrary bending arrangement of the cable in new energy vehicles. At the same time, the corrugated support ring and the annular wire can provide segmented elastic support for the cable when bending, avoiding damage to the battery core during bending. At the same time, it can improve the elasticity of the pressure, which is convenient for the rapid reset of the deformed cable. The cable connection seat is sleeved on the outside of the positioning clamp ring, and the cable connection seat is clamped and installed with the limit card strip, so that the cable is fixed by the cable connection seat and the limit card strip, so as to maintain the bending stability of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the partial structure of the present invention as a whole;

[0021] Figure 2 It is a schematic cross-sectional structure diagram of the present invention as a whole;

[0022] Figure 3 Schematic diagram of a partial cross-sectional structure of the outer protective component of the present invention;

[0023] Figure 4 Schematic diagram of the cross-sectional structure of the wear monitoring assembly of the present invention;

[0024] Figure 5 A schematic diagram of the partial structure of the wear monitoring assembly of the present invention;

[0025] Figure 6 It is a partial structural diagram of the inner layer protection component of the present invention;

[0026] Figure 7 Schematic diagram of the cross-sectional structure of the inner layer protection component of the present invention;

[0027] Figure 8 Schematic diagram of a partial cross-sectional structure of a battery cell unit of the present invention;

[0028] Figure 9 It is a schematic diagram of the partial cross-sectional structure of the central support assembly of the present invention.

[0029] In the figure: 1. Outer protective assembly; 101. Flame retardant layer; 102. Annular arc groove; 103. Positioning clamp; 104. Cable connection seat; 105. Limiting clamp; 106. Filling layer; 107. Arc mounting ring; 108. Ring wire; 109. Corrugated support ring; 110. Elastic filling ring; 2. Wear monitoring assembly; 201. First metal layer; 202. First insulating shielding layer; 203. Second metal layer; 204. Spiral braided layer; 3. Inner protective assembly; 301. Thermal conductive filling body; 302. Insulating pressure ring; 303. Sheet thermistor; 304. Elastic separator; 4. Battery cell unit; 401. Second insulating shielding layer; 402. Reinforced ridge; 403. Anti-wear layer; 404. Battery cell body; 5. Center support assembly; 501. Connection layer; 502. Center metal strip; 503. Spiral support strip. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0031] See also Figures 1 to 3 , the present invention provides an embodiment: a composite cable for new energy vehicles, including an outer protective component 1 and a wear monitoring component 2, the outer protective component 1 includes a filling layer 106, the outer surface of the filling layer 106 is provided with a plurality of annular arc grooves 102, the inner side of the annular arc groove 102 is installed with an arc-shaped mounting ring 107, the interior of the arc-shaped mounting ring 107 is provided with a plurality of annular wires 108, the outer side of the filling layer 106 is installed with a flame retardant layer 101, the filling layer 106 is bonded and fixed to the flame retardant layer 101, the arc-shaped mounting ring 107 is arranged between the flame retardant layer 101 and the filling layer 106, the filling layer 106 and the annular wire 108 are fixedly connected by the arc-shaped mounting ring 107, so that the cable can be bent arbitrarily through the annular arc groove 102 and the arc-shaped mounting ring 107, which is convenient for arranging the cable in the new energy vehicle;

[0032] A plurality of positioning clamps 103 are installed on the outside of the flame retardant layer 101, a cable connection seat 104 is installed on the outside of one of the positioning clamps 103, and limiting clamping strips 105 are installed at both ends of the cable connection seat 104. A plurality of corrugated support rings 109 are installed inside the filling layer 106, and elastic filling rings 110 are installed on both sides of each corrugated support ring 109. The positioning clamp 103 is bonded and fixed to the flame retardant layer 101, and a plurality of positioning heads arranged in a circle are provided on the outside of the positioning clamp 103. The positioning clamp 103 and the cable connection seat 104 are clamped and installed through a plurality of positioning heads. Both ends of the cable connection seat 104 and the limiting clamping strips 105 are clamped and installed. The corrugated support ring 109 and the annular wire 108 can provide segmented elastic support for the cable, thereby improving the elasticity under pressure and facilitating the rapid resetting of cable deformation.

[0033] See also Figure 2 、 Figure 4 and Figure 5 A wear monitoring component 2 is installed on the inner side of the outer protective component 1, and the wear monitoring component 2 includes a second metal layer 203, a first insulating shielding layer 202 is installed on the outer side of the second metal layer 203, a first metal layer 201 is installed on the outer side of the first insulating shielding layer 202, and a spiral braided layer 204 is installed on the outer side of the first metal layer 201. The first metal layer 201 and the second metal layer 203 are electrically connected, and the first metal layer 201 and the second metal layer 203 are both bonded and fixed to the first insulating shielding layer 202. The spiral braided layer 204 is composed of a plurality of spiral anti-cut strips. The spiral braided layer 204 and a plurality of corrugated support rings 109 can effectively maintain the wear resistance and anti-cut effect of the cable, and at the same time improve the automatic recovery rate of the cable after being compressed.

[0034] See also Figure 2 、 Figure 6 and Figure 7 , an inner layer protection component 3 is installed on the inner side of the wear monitoring component 2, and the inner layer protection component 3 includes a thermally conductive filling body 301, and a plurality of insulating pressure rings 302 are installed on the outer side of the thermally conductive filling body 301, and a plurality of sheet thermistors 303 are installed on the outer side of each insulating pressure ring 302, and a plurality of elastic dividing strips 304 are installed inside the thermally conductive filling body 301. The thermally conductive filling body 301 and the sheet thermistor 303 are fixedly connected through the insulating pressure ring 302, and the thermally conductive filling body 301 and the filling layer 106 are fixedly connected through the wear monitoring component 2. The plurality of sheet thermistors 303 are arranged circumferentially relative to the insulating pressure ring 302, and the plurality of insulating pressure rings 302 are arranged linearly along the axis of the thermally conductive filling body 301. According to the change in resistance value of the sheet thermistor 303 during power-on, the cable can be subjected to distributed temperature monitoring, which is convenient for timely detection of local temperature rise of the cable.

[0035] See also Figure 7 and Figure 8 A plurality of battery cell units 4 are installed on the inner side of the inner protective component 3, and the battery cell units 4 include a second insulating shielding layer 401, and a plurality of reinforcing ridges 402 are provided on the outer surface of the second insulating shielding layer 401. An anti-wear layer 403 is installed on the inner side of the second insulating shielding layer 401, and a battery cell body 404 is installed on the inner side of the anti-wear layer 403. The thermal conductive filling body 301 is fixedly connected with a plurality of elastic separators 304, and the plurality of elastic separators 304 and the plurality of second insulating shielding layers 401 are arranged in a circle relative to the axis of the thermal conductive filling body 301. An elastic separator 304 is provided between each adjacent second insulating shielding layer 401, and the elastic separator 304 and the second insulating shielding layer 401 are both coaxial with the thermal conductive filling body 301, so that the thermal conductive filling body 301 can effectively separate and shield the battery cell body 404 through the elastic separator 304, thereby keeping the distance between the two adjacent battery cell bodies 404 stable.

[0036] See also Figure 7 and Figure 9 A central support assembly 5 is installed between multiple battery cells 4. The central support assembly 5 includes a connecting layer 501. The outer surface of the connecting layer 501 is provided with a spiral support bar 503. The inner side of the connecting layer 501 is provided with a central metal bar 502. The connecting layer 501 and the central metal bar 502 can improve the connection strength of the cable center.

[0037] During use, when the cable is applied to a new energy vehicle, the central support assembly 5, the multiple battery cells 4, the inner protective assembly 3, the wear monitoring assembly 2 and the outer protective assembly 1 are sequentially assembled from the inside to the outside, so that the multiple battery cells 4 are arranged in a circle relative to the central support assembly 5, and are wrapped and fixed by the thermally conductive filling body 301 to keep the battery cells 4 and the central support assembly 5 stably installed. A central metal strip 502 is installed on the inner side of the connecting layer 501, so that the connection strength of the cable center can be improved through the connecting layer 501 and the central metal strip 502. An elastic separator 304 is installed between two adjacent second insulating shielding layers 401, so that the thermally conductive filling body 301 can effectively separate and shield the battery cell body 404 through the elastic separator 304, so that the distance between the two adjacent battery cell bodies 404 is stable.

[0038] A plurality of insulating pressure rings 302 are installed along the axis of the heat-conducting filling body 301, and a plurality of circumferentially arranged sheet thermistors 303 are installed on the outside of each insulating pressure ring 302. According to the change in the resistance value of the sheet thermistors 303 during the power-on process, the cable can be subjected to distributed temperature monitoring, which facilitates timely detection of local temperature rise of the cable. A second metal layer 203 and a first metal layer 201 are respectively installed inside and outside the first insulating shielding layer 202, so that the first metal layer 201 and the second metal layer 203 can be insulated and separated by the first insulating shielding layer 202, and the first metal layer 201 and the second metal layer 203 are maintained to monitor the wear of the cable;

[0039] Specifically, a spiral braided layer 204 is installed on the outside of the first metal layer 201, and a plurality of corrugated support rings 109 are installed inside the filling layer 106, so that the wear resistance and cut resistance of the cable can be effectively maintained by the spiral braided layer 204 and the plurality of corrugated support rings 109, while the automatic recovery rate of the cable after being compressed is improved. When the flame retardant layer 101, the filling layer 106 and the spiral braided layer 204 are subjected to external wear and damage, the electrical connection between the first metal layer 201 and the second metal layer 203 is synchronously stopped, so that the degree of damage and the damaged position of the cable can be accurately and in real time determined, thereby avoiding the risk of use caused by exposed battery cores; a plurality of rings are provided on the outside of the filling layer 106. shaped arc groove 102, and an arc-shaped mounting ring 107 is installed on the inner side of each annular arc groove 102, so that the cable can be bent arbitrarily through the annular arc groove 102 and the arc-shaped mounting ring 107, which is convenient for arranging the cables in new energy vehicles. At the same time, the corrugated support ring 109 and the annular wire 108 can provide segmented elastic support for the cable, thereby improving the elasticity under pressure and facilitating the rapid reset of cable deformation. The cable connecting seat 104 is fitted on the outer side of the flame retardant layer 101 through the positioning clamp ring 103, and the cable connecting seat 104 is clamped and installed with the limit clamp strip 105, so that the cable can be fixed by the cable connecting seat 104 and the limit clamp strip 105, so as to maintain the bending stability of the cable.

[0040] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A composite cable for new energy vehicles, comprising an outer protective component (1) and a wear monitoring component (2), characterized in that: A wear monitoring component (2) is installed on the inner side of the outer protective component (1); The outer protective component (1) includes a filling layer (106), the outer surface of the filling layer (106) is provided with a plurality of annular arc grooves (102), the inner side of the annular arc groove (102) is provided with an arc-shaped mounting ring (107), the interior of the arc-shaped mounting ring (107) is provided with a plurality of annular wires (108), the outer side of the filling layer (106) is provided with a plurality of positioning clamps (103), the outer side of one of the positioning clamps (103) is provided with a cable connection seat (104), both ends of the cable connection seat (104) are provided with limit clamps (105), the interior of the filling layer (106) is provided with a plurality of corrugated support rings (109), and both sides of each corrugated support ring (109) are provided with elastic filling rings (110); The wear monitoring component (2) comprises a second metal layer (203), a first insulating shielding layer (202) is installed on the outside of the second metal layer (203), a first metal layer (201) is installed on the outside of the first insulating shielding layer (202), and a spiral braided layer (204) is installed on the outside of the first metal layer (201); The first metal layer (201) and the second metal layer (203) are electrically connected, the first metal layer (201) and the second metal layer (203) are both bonded and fixed to the first insulating shielding layer (202), and the spiral braided layer (204) is composed of a plurality of spiral anti-cut strips.

2. A composite cable for new energy vehicles according to claim 1, characterized in that: An inner layer protection component (3) is installed on the inner side of the wear monitoring component (2), a plurality of battery cells (4) are installed on the inner side of the inner layer protection component (3), a central support component (5) is installed between the plurality of battery cells (4), the outer layer protection component (1) further comprises a flame retardant layer (101) fixedly connected to the filling layer (106), the flame retardant layer (101) is installed between the filling layer (106) and a plurality of positioning clamps (103), and a plurality of arc-shaped mounting rings (107) are all arranged between the flame retardant layer (101) and the filling layer (106).

3. A composite cable for new energy vehicles according to claim 2, characterized in that: The inner layer protection component (3) comprises a heat-conducting filling body (301), a plurality of insulating pressure rings (302) are installed on the outside of the heat-conducting filling body (301), a plurality of sheet thermistors (303) are installed on the outside of each insulating pressure ring (302), and a plurality of elastic separation strips (304) are installed inside the heat-conducting filling body (301).

4. A composite cable for new energy vehicles according to claim 3, characterized in that: The battery cell unit (4) comprises a second insulating shielding layer (401), the outer surface of the second insulating shielding layer (401) is provided with a plurality of reinforcing ridges (402), an anti-wear layer (403) is installed on the inner side of the second insulating shielding layer (401), and a battery cell body (404) is installed on the inner side of the anti-wear layer (403).

5. A composite cable for new energy vehicles according to claim 4, characterized in that: The central support assembly (5) comprises a connecting layer (501), the outer surface of the connecting layer (501) is provided with a spiral support bar (503), and the inner side of the connecting layer (501) is provided with a central metal bar (502).

6. A composite cable for new energy vehicles according to claim 5, characterized in that: The filling layer (106) is bonded and fixed to the flame retardant layer (101), the arc-shaped mounting ring (107) is arranged between the flame retardant layer (101) and the filling layer (106), and the filling layer (106) and the annular wire (108) are fixedly connected via the arc-shaped mounting ring (107).

7. A composite cable for new energy vehicles according to claim 6, characterized in that: The positioning clamp (103) is bonded and fixed to the flame retardant layer (101); a plurality of positioning heads arranged in a circumferential pattern are provided on the outer side of the positioning clamp (103); the positioning clamp (103) and the cable connection seat (104) are clamped and installed via the plurality of positioning heads; both ends of the cable connection seat (104) and the limit clamping strip (105) are clamped and installed.

8. The composite cable for new energy vehicles according to claim 3, characterized in that: The thermally conductive filling body (301) and the sheet thermistor (303) are fixedly connected via an insulating pressure ring (302); the thermally conductive filling body (301) and the filling layer (106) are fixedly connected via a wear monitoring assembly (2); a plurality of the sheet thermistors (303) are arranged circumferentially relative to the insulating pressure ring (302); and a plurality of the insulating pressure rings (302) are arranged linearly along the axis of the thermally conductive filling body (301).

9. A composite cable for new energy vehicles according to claim 8, characterized in that: The heat-conducting filling body (301) is fixedly connected to a plurality of elastic separation strips (304); the plurality of elastic separation strips (304) and the plurality of second insulating shielding layers (401) are arranged in a circle relative to the axis of the heat-conducting filling body (301); an elastic separation strip (304) is provided between two adjacent second insulating shielding layers (401); and the elastic separation strip (304) and the second insulating shielding layer (401) are coaxial with the heat-conducting filling body (301).

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