An insulating ultra-fine bare copper stranded wire for a new energy vehicle horn and a stranded wire terminal

Abstract

The application relates to the technical field of electric wire and cable, and discloses an insulated extremely fine bare copper stranded wire for a new energy automobile horn and a stranded wire terminal, which comprises a stranded wire main body, the stranded wire main body is centered on an enameled wire, a twisted cotton silk wire is arranged outside the enameled wire, a conductive rubber layer is arranged outside the twisted cotton silk wire, a nanocrystalline alloy strip is embedded in the conductive rubber layer, the nanocrystalline alloy strip is wrapped outside the twisted cotton silk wire through a spiral winding process, an annular elastic sheath is arranged outside the conductive rubber layer, an outer coating layer is arranged outside the annular elastic sheath and the conductive rubber layer, a micro memory alloy spring is embedded in the gap between the annular elastic sheath and the outer coating layer, and a connecting head is fixedly connected to one end of the stranded wire main body. In the application, the twisted cotton silk wire, the nanocrystalline alloy strip, the conductive rubber layer, the annular elastic sheath and the outer coating layer and other multi-layer structures jointly act to realize stable audio signal transmission and ensure long-term reliable operation under complex working conditions of the automobile.

Description

Technical Field

[0001] This invention relates to the field of wire and cable technology, and in particular to an insulated ultra-fine bare copper stranded wire and stranded wire terminal for use in new energy vehicle horns. Background Technology

[0002] In automotive electrical systems, signal transmission and electrical connections rely on stranded wires and terminals. Traditional bare copper stranded wires used in new energy vehicle horns typically use ordinary copper wire as the conductor, with an outer plastic insulation layer, only fulfilling basic conductivity and insulation functions. These wires lack flexibility and cannot withstand the continuous vibrations during vehicle operation, easily leading to conductor breakage and insulation damage. Furthermore, the lack of effective electromagnetic shielding means that electromagnetic interference from the vehicle's high-voltage system and motor can severely affect audio signal transmission quality, causing abnormal horn sound. Traditional stranded wire terminals often use simple plug-in or screw-fastening connections, making installation cumbersome and prone to loosening under vibration, resulting in unstable electrical connections and increased contact resistance. This not only increases installation and maintenance costs but may also cause safety issues.

[0003] While traditional stranded wires and terminals have played a role in automotive electrical connections, their shortcomings are becoming increasingly apparent with the continuous innovation of new energy vehicle technology. As the powertrain systems of new energy vehicles become more complex, the electromagnetic environment inside the vehicle becomes more severe. Traditional stranded wires, lacking multi-layered shielding structures and vibration-resistant designs, cannot withstand high-frequency electromagnetic interference and mechanical vibration, making it difficult to ensure stable audio signal transmission. Furthermore, traditional stranded wire terminals cannot achieve rapid and precise connection, and long-term vibration can easily lead to connection failure, failing to meet the high reliability and ease of maintenance requirements of automotive electrical systems. Therefore, developing new stranded wires and terminals with multi-layered protection and efficient connection functions has become crucial for improving the performance of new energy vehicle electrical systems.

[0004] To address the aforementioned issues, an insulated ultra-fine bare copper stranded wire and stranded wire terminals for new energy vehicle horns are proposed. Summary of the Invention

[0005] To overcome the above deficiencies, the present invention provides an insulated ultra-fine bare copper stranded wire and stranded wire terminal for new energy vehicle horns, aiming to improve the problems of poor vibration resistance, poor shielding, low connection efficiency and insufficient stability of existing stranded wires and terminals for new energy vehicle horns.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] An insulated ultra-fine bare copper stranded wire for new energy vehicle horns includes a stranded wire body. The stranded wire body is centered on an enameled wire, with stranded nylon wires arranged on the outer side of the enameled wires. A conductive rubber layer is arranged on the outer side of the stranded nylon wires. A nanocrystalline alloy strip is embedded inside the conductive rubber layer, and the nanocrystalline alloy strip is wrapped around the outer side of the stranded nylon wires by a spiral winding process. An annular elastic sheath is sleeved on the outer side of the conductive rubber layer. An outer sheath is sleeved on the outer side of the annular elastic sheath and the conductive rubber layer. A micro memory alloy spring is embedded in the gap between the annular elastic sheath and the outer sheath. A connector is fixedly connected to one end of the stranded wire body.

[0008] As a further description of the above technical solution:

[0009] The enameled wire, stranded nylon wire, nanocrystalline alloy strip, conductive rubber layer, annular elastic sheath, and outer sheath are arranged coaxially from the inside to the outside, and the layers are connected by appropriate wrapping, stranding or sleeving processes.

[0010] As a further description of the above technical solution:

[0011] The stranded nylon wire is composed of 7 strands of monofilaments twisted together from 49 strands of insulated, extremely fine bare copper strands.

[0012] As a further description of the above technical solution:

[0013] The annular elastic sheath is nested in the "twisted contact area" of the twisted nylon thread;

[0014] A stranded wire terminal adapted to the above-described insulated ultra-fine bare copper stranded wire for new energy vehicle horns includes a terminal body, the terminal body includes a base, an outer shell is provided on the outer side of the base, an insulating pad is installed inside the outer shell, a trigger is provided inside the outer shell, a locking element is provided at both the upper and lower ends of the trigger, a locking element is provided at the adjacent end of the locking element, an external interface is provided on the top of the base, and a connector is used to connect the insulated ultra-fine bare copper stranded wire to the terminal body;

[0015] As a further description of the above technical solution:

[0016] The triggering element includes a contact post, a return spring, and a follower plate. The contact post passes through the outer shell, one end of the return spring abuts against the inner wall of the outer shell, and the other end of the return spring is connected to the contact post. The two follower plates are fixedly connected to the upper and lower sides of the contact post, respectively.

[0017] As a further description of the above technical solution:

[0018] The locking component includes a horizontal locking post, a vertical locking post, a contact plate, and a compression spring. The horizontal locking post is fixedly connected to the follower plate, and the vertical locking post is slidably connected inside the outer shell. Both the vertical locking post and the horizontal locking post have locking grooves on their outer sides. The far ends of the two sets of vertical locking posts are fixedly connected to the contact plate, and a compression spring is provided between the contact plate and the outer shell. The compression spring is sleeved on the outside of the vertical locking post.

[0019] As a further description of the above technical solution:

[0020] The engaging component includes an elastic retaining ring, an L-shaped metal spring, a docking seat, and a slot. The elastic retaining ring is fixedly connected to the other end of the vertical engaging post. The L-shaped metal spring is fixedly installed inside the elastic retaining ring. The docking seat is correspondingly set on the connecting head, and a slot is opened inside the docking seat to fit the L-shaped metal spring.

[0021] As a further description of the above technical solution:

[0022] Driven by the vertical locking post, the elastic retaining ring can achieve radial contraction or opening. The L-shaped metal spring moves with the elastic retaining ring, and is adapted to engage or disengage with the mating seat and slot on the connector head.

[0023] The present invention has the following beneficial effects:

[0024] 1. In this invention, the insulated ultra-fine bare copper stranded wire is based on enameled wire and is wrapped in multiple layers, including stranded nylon wire, nanocrystalline alloy strip, conductive rubber layer, annular elastic sheath, and outer sheath, in conjunction with a micro-memory alloy spring. The stranded nylon wire provides flexibility and fatigue resistance; the nanocrystalline alloy strip and conductive rubber layer form double electromagnetic shielding, effectively reducing high-frequency interference; the annular elastic sheath and memory alloy spring enhance vibration resistance, resisting vehicle vibration; and the outer sheath isolates the wire from the corrosive effects of complex environments. The combined effect of these multiple layers achieves stable audio signal transmission, ensuring long-term reliable operation under complex automotive conditions.

[0025] 2. In this invention, the stranded wire terminals achieve efficient connection through a precise linkage design of triggering elements, locking elements, and engaging elements. When the connector head presses against the contact post, it triggers the compression of the return spring, which drives the follower plate and the horizontal engaging post to move, aligning the horizontal and vertical engaging post slots. This triggers the compression spring to push the vertical engaging post closed, causing the elastic retaining ring and L-shaped metal spring to engage with the mating seat slot, completing a secure connection. During disassembly, the contact plate opens, causing the vertical engaging post to separate, achieving quick unlocking. This structure enables rapid and reliable connection and convenient disassembly of the stranded wire and terminal, significantly improving installation efficiency and maintenance convenience, and ensuring the long-term stability of the electrical connection. Attached Figure Description

[0026] Figure 1This is an assembly diagram of an insulated ultra-fine bare copper stranded wire and stranded wire terminal for a new energy vehicle horn, as proposed in this invention.

[0027] Figure 2 This is a schematic diagram of the structure of the stranded body of an insulated ultra-fine bare copper stranded wire for a new energy vehicle horn, as proposed in this invention.

[0028] Figure 3 This is a schematic diagram of the structure of a stranded nylon wire for an insulated ultra-fine bare copper stranded wire for a new energy vehicle horn, as proposed in this invention.

[0029] Figure 4 This is a schematic cross-sectional view of an insulated ultra-fine bare copper stranded wire for a new energy vehicle horn, as proposed in this invention.

[0030] Figure 5 This is a three-dimensional schematic diagram of an insulated ultra-fine bare copper stranded wire terminal for a new energy vehicle horn proposed in this invention;

[0031] Figure 6 This is a schematic diagram of the trigger element for an insulated ultra-fine bare copper stranded wire terminal for a new energy vehicle horn, as proposed in this invention.

[0032] Figure 7 This is a schematic diagram of the structure of a locking component for an insulated ultra-fine bare copper stranded wire terminal for a new energy vehicle horn, as proposed in this invention.

[0033] Figure 8 This is a schematic diagram of the structure of an insulated ultra-fine bare copper stranded wire and a connector for a stranded wire terminal for a new energy vehicle horn, as proposed in this invention.

[0034] Figure 9 for Figure 8 Enlarged view of point A in the middle.

[0035] Legend:

[0036] 1. Stranded wire body; 101. Enamelled wire; 102. Stranded nylon wire; 103. Conductive rubber layer; 104. Nanocrystalline alloy strip; 105. Annular elastic sheath; 106. Outer sheath layer; 107. Miniature memory alloy spring; 2. Connector; 3. Terminal body; 31. Base; 32. Outer shell; 33. Insulating pad; 34. Trigger; 341. Contact post; 342. Return spring; 343. Follower plate; 35. Locking element; 351. Horizontal locking post; 352. Vertical locking post; 353. Contact plate; 354. Compression spring; 36. Engaging element; 361. Elastic retaining ring; 362. L-shaped metal spring; 363. Connecting seat; 364. Slot; 37. External interface. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1: Refer to Figures 1 to 4 A type of insulated ultra-fine bare copper stranded wire for new energy vehicle horns includes a stranded wire body 1, with enameled wire 101 at its center. The enameled wire 101 is made of high-purity oxygen-free copper, and the insulating varnish coating on its surface provides electrical isolation and a supporting foundation for the outer structure, serving as the core conductor for signal transmission. A stranded nylon wire 102 is stranded and wrapped around the outside of the enameled wire 101. The stranded nylon wire 102 is composed of 7 single strands formed by stranding 49 strands of insulated ultra-fine bare copper stranded wire. The multi-strand stranding design gives the wire flexibility and fatigue resistance. The conductive rubber layer 103 is disposed on the outside of the stranded cotton filaments 102. A nanocrystalline alloy strip 104 is embedded inside the conductive rubber layer 103 and is wrapped around the outside of the stranded cotton filaments using a spiral winding process. The nanocrystalline alloy strip 104 utilizes its high magnetic permeability to absorb high-frequency electromagnetic waves generated by the vehicle's high-voltage system and motor, thus weakening electromagnetic interference. The conductive rubber layer 103 is composed of a silicone rubber matrix filled with silver powder, filling the winding gaps of the nanocrystalline alloy strip 104 to form a continuous... Following the electromagnetic shielding layer, the flexibility and temperature resistance of silicone rubber isolate moisture and dust, achieving insulation and initial protection. An annular elastic sheath 105 is fitted over the conductive rubber layer 103, nested within the "stretching contact area" of the stranded filament wire 102. Through elastic deformation, it absorbs and buffers external forces, preventing the stranded filaments from breaking due to vibration and improving the wire's vibration resistance. An outer sheath 106 wraps around the annular elastic sheath 105 and the conductive rubber layer 103, using weather-resistant materials to resist high temperatures and oil contamination inside the vehicle. The stranded wire is protected against corrosion from complex environments such as ultraviolet radiation. A miniature shape memory alloy spring 107 is embedded in the gap between the annular elastic sheath 105 and the outer sheath 106. Utilizing the shape memory effect and superelasticity of the shape memory alloy, it assists the annular elastic sheath 105 in resetting, enhancing the stranded wire's resistance to deformation and adapting to temperature changes and external forces. One end of the stranded wire body 1 is fixedly connected to a connector 2. The material of the connector 2 matches the stranded nylon wire 102, and electrical conductivity is ensured through a welding process, providing an interface for the connection between the stranded wire and the terminal.

[0039] Enameled wire 101, stranded nylon wire 102, nanocrystalline alloy strip 104, conductive rubber layer 103, annular elastic sheath 105, and outer sheath 106 are arranged coaxially from the inside to the outside. The layers are connected by appropriate wrapping, stranding or sleeving processes to form a multi-layered synergistic system of "conductivity-shielding-vibration resistance-protection".

[0040] Example 2: Refer to Figures 5 to 9 A stranded wire terminal adapted to the aforementioned insulated ultra-fine bare copper stranded wire for new energy vehicle horns includes a terminal body 3, which includes a base 31. The base 31 serves as the mounting foundation for the terminal body 3, providing stable support for the entire structure. An outer shell 32 is provided on the outside of the base 31, covering the outside of the base 31 and providing mechanical support and protection for internal trigger elements 34, locking elements 35, etc., while also forming a guide structure for the insertion of the connector 2. An insulating pad 33 is installed inside the outer shell 32, isolating the electrical connection between the base 31 and the outer shell 32 to prevent short circuits and improve the insulation performance of the terminal. A trigger element 34 is provided inside the outer shell 32, with locking elements 35 at both the upper and lower ends of the trigger element 34. A locking element 36 is provided at the adjacent end of the locking element 35. An external interface 37 is provided on the top of the base 31, which is used for electrical connection between the terminal body 3 and the car horn or other external circuit systems to achieve signal transmission. The connector 2 is used to connect the insulated ultra-fine bare copper stranded wire to the terminal body 3.

[0041] The trigger 34 includes a contact post 341, a return spring 342, and a follower plate 343. The contact post 341 passes through the outer shell 32. When the connector 2 is inserted, it is squeezed and compresses the return spring 342, which in turn drives the follower plate 343 to move. One end of the return spring 342 abuts against the inner wall of the outer shell 32, and the other end is connected to the contact post 341. When the contact post 341 is squeezed, it stores elastic potential energy. After the external force disappears, it pushes the contact post 341 to reset. The two follower plates 343 are fixedly connected to the upper and lower sides of the contact post 341, respectively. As the contact post 341 moves, they drive the horizontal locking post 351 to move.

[0042] The locking component 35 includes a horizontal locking post 351, a vertical locking post 352, a contact plate 353, and a compression spring 354. The horizontal locking post 351 is fixedly connected to the follower plate 343, and moves with the follower plate 343 to make its locking groove correspond to the locking groove of the vertical locking post 352. The vertical locking post 352 is slidably connected inside the outer shell 32, and both the outer sides of the vertical locking post 352 and the horizontal locking post 351 are provided with locking grooves. The far ends of the two sets of vertical locking posts 352 are fixedly connected to the contact plate 353. A compression spring 354 is provided between the contact plate 353 and the outer shell 32. The compression spring 354 is sleeved on the outer side of the vertical locking post 352. When the horizontal locking post 352 and the vertical locking post 352 are aligned, the compression spring 354 pushes the vertical locking post 352 to close and lock. When the contact plate 353 is operated, it drives the vertical locking post 352 to separate and unlock.

[0043] The locking component 36 includes an elastic retaining ring 361, an L-shaped metal spring 362, a mating seat 363, and a locking groove 364. The elastic retaining ring 361 is fixedly connected to the other end of the vertical locking post 352, and achieves radial contraction or opening as the vertical locking post 352 closes or separates. The L-shaped metal spring 362 is fixedly installed inside the elastic retaining ring 361, and engages or disengages from the locking groove 364 of the mating seat 363 as the elastic retaining ring 361 moves. The mating seat 363 is correspondingly disposed on the connector 2, and the locking groove 364 is provided inside the mating seat 363. The locking groove 364 is adapted to the L-shaped metal spring 362 to achieve mechanical and electrical connection and fixation between the stranded wire and the terminal.

[0044] The elastic retaining ring 361 can achieve radial contraction or opening under the action of the vertical retaining post 352. The L-shaped metal spring 362 moves with the elastic retaining ring 361 and is adapted to engage or disengage with the mating seat 363 and the slot 364 on the connector 2. The "trigger-lock-engage" linkage mechanism enables quick insertion and removal and reliable locking.

[0045] Working principle: The ultra-fine bare copper stranded wire used in new energy vehicle horns uses enameled wire 101 as its core, with its surface insulating varnish layer providing electrical isolation and basic support. 49 bare copper monofilaments are first twisted into 7 monofilaments, then twisted a second time into a stranded nylon wire 102 that tightly wraps around the enameled wire 101. Precise control of the twisting tension ensures the monofilaments are evenly arranged, giving the stranded wire flexibility and fatigue resistance, dispersing external forces from vehicle vibrations, and providing mechanical strength.

[0046] On the outside of the stranded nylon wire 102, a nanocrystalline alloy strip 104 is spirally wound to absorb the high-frequency electromagnetic waves generated by the high-voltage system and motor of the car, thereby weakening electromagnetic interference. A conductive rubber layer 103 is covered to fill the gaps in the nanocrystalline alloy strip 104 with the help of the flexibility and temperature resistance of silicone rubber and the conductivity of silver powder, so as to achieve continuous electromagnetic shielding and isolate moisture and dust, thus achieving insulation and preliminary protection.

[0047] An annular elastic sheath 105 is nested in the stress concentration area of ​​the stranded nylon wire 102. It absorbs and buffers external forces through elastic deformation, preventing single wire breakage and improving the vibration resistance of the stranded wire. The outer sheath 106 is wrapped with weather-resistant material to resist the corrosion of the complex automotive environment. A micro memory alloy spring 107 is embedded in the gap, which uses its shape memory effect and superelasticity to assist the sheath in restoring and enhance the resistance to deformation.

[0048] Each layer is coaxially connected through processes such as stranding, winding, and extrusion. One end of the stranded wire is welded to a connector 2 to ensure electrical conductivity, ultimately forming a complete structure that stably transmits audio signals, withstands complex automotive conditions, and is suitable for the horn requirements of new energy vehicles.

[0049] When connecting the insulated ultra-fine bare copper stranded wire to the terminal body 3, first align the connector 2 of the stranded wire with the corresponding interface of the terminal body 3. At this time, the connector 2 contacts the contact post 341 of the trigger 34, and under the action of horizontal insertion force, the connector 2 presses the contact post 341 backward. After the contact post 341 is compressed, it drives the reset spring 342 connected to it to compress. At the same time, the follower plates 343 on the upper and lower sides of the contact post 341 move backward synchronously. During the movement of the follower plates 343, they drive the horizontal locking post 351 fixed to them to move together, so that the locking groove on the horizontal locking post 351 gradually aligns with the locking groove on the vertical locking post 352. When the locking grooves of the two are aligned, the originally compressed spring 354 begins to recover its deformation, pushing the vertical locking post 352 to close in the middle. When the vertical locking post 352 moves, it drives the elastic retaining ring 361 fixedly connected to its other end to close in the middle synchronously. Under the continuous action of this horizontal insertion, the L-shaped metal spring 362 inside the elastic retaining ring 361 moves with the elastic retaining ring 361 and is precisely engaged in the corresponding docking seat 363 on the connector 2. The L-shaped metal spring 362 and the slot 364 opened inside the docking seat 363 are adapted and engaged to complete the snap-fit ​​and fixation of the stranded wire and the terminal body 3.

[0050] To remove the cable, operate the contact plate 353 to open the two contact plates 353. The contact plates 353 drive the vertical locking post 352 to move to both sides, and the elastic retaining ring 361 opens accordingly. The L-shaped metal spring 362 separates from the docking seat 363 and the slot 364. At the same time, the horizontal locking post 351 moves in the opposite direction, and the contact post 341 is reset under the restoring force of the return spring 342, so that the stranded wire can be pulled out from the terminal body 3.

[0051] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended 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 make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A stranded terminal for an insulated very fine bare copper stranded wire for a new energy vehicle horn, comprising a terminal main body (3), characterized in that: The terminal body (3) comprises a base (31), an outer shell (32) is arranged on the outer side of the base (31), an insulating pad (33) is arranged on the inner side of the outer shell (32), a trigger (34) is arranged in the inner part of the outer shell (32), locking pieces (35) are arranged on the upper and lower ends of the trigger (34), a clamping piece (36) is arranged on the proximal end of the locking piece (35), an external interface (37) is arranged on the top of the base (31), and the connecting head (2) is used for connecting the insulating extremely thin bare copper stranded wire and the terminal body (3); The trigger (34) comprises a contact column (341), a reset spring (342) and a follow-up plate (343), the contact column (341) is arranged in the outer shell (32), one end of the reset spring (342) abuts against the inner wall of the outer shell (32), and the other end of the reset spring (342) is connected with the contact column (341), and two follow-up plates (343) are fixedly connected on the upper and lower sides of the contact column (341); The locking piece (35) comprises a horizontal clamping column (351), a vertical clamping column (352), a contact plate (353) and a compression spring (354), the horizontal clamping column (351) is fixedly connected with the follow-up plate (343), the vertical clamping column (352) is slidingly connected in the inner part of the outer shell (32), clamping grooves are arranged on the outer sides of the vertical clamping column (352) and the horizontal clamping column (351), the distal ends of the two vertical clamping columns (352) are fixedly connected with the contact plates (353), the compression springs (354) are arranged between the contact plates (353) and the outer shell (32), and the compression springs (354) are sleeved on the outer sides of the vertical clamping columns (352); The clamping piece (36) comprises an elastic clamping ring (361), an L-shaped metal elastic sheet (362), a butt joint seat (363) and a clamping groove (364), the elastic clamping ring (361) is fixedly connected on the other end of the vertical clamping column (352), the L-shaped metal elastic sheet (362) is fixedly arranged in the inner side of the elastic clamping ring (361), the butt joint seat (363) is correspondingly arranged on the connecting head (2), and the clamping groove (364) is arranged in the inner part of the butt joint seat (363) and is adapted to the L-shaped metal elastic sheet (362).

2. The stranded terminal of the insulated ultra-fine bare copper stranded wire for a horn of a new energy vehicle according to claim 1, characterized in that: The elastic clamping ring (361) can realize radial contraction or expansion action under the driving of the vertical clamping column (352), and the L-shaped metal elastic sheet (362) can be adapted to the butt joint seat (363) and the clamping groove (364) on the connecting head (2) for clamping or separation.

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