Photoelectric composite cable for vehicle and new energy vehicle using photoelectric composite cable

Abstract

The invention belongs to the technical field of photoelectric composite cables, and particularly relates to a vehicle photoelectric composite cable which comprises two optical units and a connecting neck connected between the two optical units. Each optical unit comprises a tightly-packaged optical fiber, an aramid fiber reinforcement layer wrapping the periphery of the tightly-packaged optical fiber, and an outer sheath located on the outermost layer; wherein the outer sheath comprises an outer sheath main body and at least three super-soft annealed bare copper conductors, the outer sheath main body wraps the aramid fiber reinforcement layer, and the at least three super-soft annealed bare copper conductors are uniformly located in the outer sheath main body in a circumferential array manner by taking the axis of the tightly-wrapped optical fiber as a circle center; the high-temperature-resistant high-temperature-resistant electromagnetic valve has the beneficial effects of high temperature resistance, chemical stability, low friction characteristic, hot and humid environment resistance, oil corrosion resistance, high electromagnetic interference resistance, external diameter miniaturization, great improvement of heat dissipation performance, high mechanical stress resistance and the like; the invention further discloses a new energy automobile.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of optical-electrical composite cables, and particularly relates to a vehicle optical-electrical composite cable and a new energy vehicle using the same. BACKGROUND

[0002] At present, the wide application of traditional vehicle optical-electrical composite cables in vehicle electronic systems exposes several structural defects, mainly in the following three aspects: Firstly, the structure is bulky and has poor space adaptability. The power transmission conductor used by the current low-voltage control unit is mostly in a twisted structure, such as a Φ0.08mm×19 twisted conductor. The single wire diameter is extremely small, but the overall outer diameter is usually not less than 0.4mm. This structure causes the overall diameter of the cable to be large, making it difficult to pass through the increasingly miniaturized connector interface in modern automotive electronic modules, especially in ADAS sensors, vehicle cameras and domain controllers, etc. highly integrated devices, making wiring difficult, limiting its installation and application in compact electronic units.

[0003] Secondly, there are significant defects in thermal management performance. There are a large number of micro air gaps between the twisted conductors, which act as thermal barriers during heat transfer, significantly reducing the heat dissipation efficiency of the conductors. In the long-term high-load running state of the vehicle, the heat generated by the current is difficult to quickly dissipate, which is easy to cause local temperature accumulation and cause overheating. Continuous high temperature will accelerate the aging process of the insulation material, reduce its dielectric strength, and even cause short circuit risk, affecting the electrical safety and service life of the vehicle.

[0004] Thirdly, the mechanical stability is insufficient. During vehicle driving, the vehicle continuously faces mechanical stress such as vibration, impact and repeated bending. The twisted conductor is prone to relative slip and micro deformation between the single wires when stressed. This displacement will cause the DC resistance of the conductor to change, causing impedance fluctuations, which in turn causes the quality of signal transmission to decline or the power transmission to be unstable, which may affect the normal operation of the key control unit and reduce the overall reliability of the system.

[0005] In the prior art, CN210606771U discloses an optical-electrical composite cable for electric vehicle charging pile: including parallel arranged cables and optical cables, connected by connecting ribs, the cable from inside to outside is DC conductor, ribbon, insulation layer, metal braid layer and cable outer sheath, the optical cable from inside to outside is optical fiber, low-smoke halogen-free tight sleeve layer, stainless steel spiral armor pipe, metal braid layer, aramid fiber reinforcing layer and optical cable outer sheath, the cable outer sheath, optical cable outer sheath and connecting rib are integrally formed by using EPDM material.

[0006] The above prior art has defects such as poor mechanical stability and poor heat dissipation capacity.

[0007] In summary, the existing optical-electric composite cable has obvious shortcomings in structural design, heat dissipation capacity and mechanical robustness, which need to be solved urgently. SUMMARY

[0008] The application provides a vehicle optical-electric composite cable, which significantly improves the integration, heat dissipation and reliability of the new energy vehicle optical-electric composite cable by adopting tightly packed high-temperature-resistant optical fibers, circumferential array conductor-heat dissipation integrated structure and a triple mechanical protection system, and is suitable for the vehicle-mounted environment with high density and high frequency vibration such as a three-electric system and ADAS.

[0009] In order to achieve the above-mentioned target, the application adopts the following technical solutions: A vehicle optical-electric composite cable comprises: Two optical units and a connecting neck connected between the two optical units, the connecting neck being used for structural transition and stress relief; each optical unit comprises tightly packed optical fibers, an aramid fiber reinforced layer wrapped around the periphery of the tightly packed optical fibers, and an outer sheath located at the outermost layer. The outer sheath comprises an outer sheath body and at least three super-soft annealed bare copper conductors, the outer sheath body wraps the aramid fiber reinforced layer, and the at least three super-soft annealed bare copper conductors are uniformly located in the outer sheath body in a circumferential array manner with the axis of the tightly packed optical fibers as the center.

[0010] The vehicle optical-electric composite cable comprises a plurality of conductor accommodating cavity groups formed inside the outer sheath body with the axis of the tightly packed optical fibers as the center, each conductor accommodating cavity group comprises two accommodating cavities and an arc-shaped hole, the two accommodating cavities are in communication with the arc-shaped hole, and one super-soft annealed bare copper conductor is arranged in each accommodating cavity.

[0011] The vehicle optical-electric composite cable comprises a first accommodating cavity, a second accommodating cavity, an arc-shaped hole and a connecting cavity, the first accommodating cavity is in communication with one end of the arc-shaped hole, the second accommodating cavity is located in the region formed by the axis of the tightly packed optical fibers and the line connecting the two end portions of the arc-shaped hole, and the second accommodating cavity is in communication with the arc-shaped hole through the connecting cavity.

[0012] The width of the connecting cavity is smaller than the diameter of the accommodating cavity, the width of the arc-shaped hole is smaller than the diameter of the accommodating cavity, and the super-soft annealed bare copper conductor is in close contact with the inner wall of the accommodating cavity.

[0013] The aforementioned automotive optical-electric composite cable includes each conductor receiving cavity group comprising a first receiving cavity, a second receiving cavity, an arc-shaped hole, and a connecting cavity. The first receiving cavity and the second receiving cavity are located in the area formed by the line connecting the two ends of the arc-shaped hole and the axis of the tightly wrapped optical fiber, and the first receiving cavity and the second receiving cavity are connected to the arc-shaped hole through the connecting cavity.

[0014] In the aforementioned automotive optical-electric composite cable, the width of the connecting cavity is smaller than the diameter of the receiving cavity, the width of the arc-shaped hole is smaller than the diameter of the receiving cavity, and the ultra-flexible annealed bare copper conductor is tightly attached to the inner wall of the receiving cavity.

[0015] The aforementioned automotive optical-electric composite cable has an arc-shaped hole that coincides with the axis of the tightly packed optical fiber. The first and second receiving cavities are symmetrically arranged about the axis of symmetry of the arc-shaped hole.

[0016] The aforementioned automotive optoelectronic composite cable includes a tight-packed optical fiber comprising a high-temperature resistant optical fiber and a tight-packed layer of polytetrafluoroethylene material covering the high-temperature resistant optical fiber.

[0017] The aforementioned automotive optical-electric composite cable has an outer sheath primarily made of thermoplastic polyurethane material, which possesses high elasticity, oil resistance, and fatigue resistance.

[0018] The aforementioned automotive optical-electric composite cable uses high-temperature resistant optical fiber (such as OM3 / OM4 grade) with bending toughness and low attenuation characteristics, and its operating temperature range can reach -60℃ to 150℃.

[0019] The aforementioned automotive optoelectronic composite cable has a tight-closing layer thickness controlled between 0.3 and 0.35 mm to ensure excellent high-temperature resistance, chemical corrosion resistance, and micro-bending resistance.

[0020] The aforementioned automotive optical-electric composite cable has a tight-closing layer that is coated onto the surface of the high-temperature resistant optical fiber using an extrusion coating process.

[0021] The aforementioned automotive optoelectronic composite cable features an aramid fiber reinforcement layer made of multiple aramid yarns wrapped longitudinally around the tightly packed optical fiber, providing a tensile strength of not less than 200N to effectively resist tensile stress during installation and use.

[0022] The aforementioned automotive optoelectronic composite cable preferably has an outer diameter of 2.0±0.1mm for the optical unit, and is suitable for miniature automotive connectors such as Mini-FAKRA and MATE-AX.

[0023] A new energy vehicle includes the aforementioned vehicle-mounted optical fiber composite cable.

[0024] A preparation method of a vehicle optical-electric composite cable, for preparing the vehicle optical-electric composite cable described above, comprising the following steps: Step 01: tight package treatment of optical fiber; high-temperature-resistant optical fiber is subjected to tight package covering through a polytetrafluoroethylene extruder to form a tight package optical fiber with uniformity and no defects; Step 02: aramid wrapping; aramid fiber is wrapped on the outer surface of the tight package optical fiber by a high-speed wrapping machine to form an aramid fiber reinforced layer; Step 03: conductor arrangement and sheath co-extrusion; after all the super-soft annealed bare copper conductors are positioned through a guide die, they are co-extruded with thermoplastic polyurethane outside the aramid fiber reinforced layer to form an outer sheath, ensuring accurate positioning of the conductors and dense combination with the sheath; Step 04: cooling and winding; segmented cooling is performed through a water cooling tank to control the cooling rate to prevent structural deformation, and finally the cable is formed through a tension control winding system and is wound on a cable reel.

[0025] The preparation method of the vehicle optical-electric composite cable described above, in the step 01, the extrusion temperature of the polytetrafluoroethylene is controlled at 250-380℃.

[0026] The preparation method of the vehicle optical-electric composite cable described above, in the step 03, the die temperature is controlled at 170-185℃ and the pressure is kept at 12-15MPa during the extrusion of the thermoplastic polyurethane.

[0027] The present application has the following beneficial effects: 1. Polytetrafluoroethylene (PTFE, commonly known as Teflon) is used as the tight package layer of the optical fiber. This material has excellent high-temperature resistance, chemical stability and low friction characteristics. The tight package structure provides reliable mechanical protection and signal isolation for the optical fiber, which can work stably in the range of -60℃ to +200℃, effectively resisting the humid and hot environment, oil corrosion and electromagnetic interference during vehicle operation, ensuring low loss and high bandwidth transmission performance of optical signals in complex vehicle-mounted environments, and is especially suitable for high-speed data transmission scenarios such as vehicle-mounted networks, laser radars and cameras.

[0028] 2. Integrated structure design of conductor-distributed heat dissipation Innovatively, multiple super-soft annealed bare copper conductors are uniformly arranged in a circumferential array in the polyurethane (TPU) outer sheath, realizing the collaborative optimization of structure and heat dissipation: Miniaturization of outer diameter: Compared with the traditional twisted structure, this design "divides the whole into parts", integrating the power transmission unit into the cable body without changing the original outer diameter of the optical cable, successfully realizing optical-electric composite. This structure significantly improves the space utilization efficiency and can adapt to miniaturized connectors (such as MATE-AX, Mini-FAKRA, etc.), meeting the requirements of high integration and narrow wiring of new energy vehicle electronic modules.

[0029] Significant improvement in heat dissipation performance: the conductor is in direct contact with the polyurethane sheath, and the total effective heat dissipation surface area is increased by 335.8% compared with the traditional twisted structure, eliminating the thermal barrier formed by the air gap between the conductors. The polyurethane material has good thermal conductivity (thermal conductivity coefficient ≥ 0.2 W / m·K), which can quickly conduct the heat generated during current transmission to the external environment, avoiding excessive local temperature rise. Experiments show that the temperature rise under rated current is reduced by more than 40%, significantly delaying insulation aging and improving long-term current-carrying reliability.

[0030] 3. Triple protection system against mechanical stress In view of the harsh working conditions of new energy vehicles such as frequent vibration, bending, and pulling, a multi-level mechanical protection system is constructed: Teflon tight layer: provides the first protection, temperature resistance ≥ 150℃, ensures that the optical fiber still maintains good mechanical strength and signal integrity in high temperature environment; Aramid fiber reinforced layer: wrapped around the optical fiber unit, providing a tensile strength of ≥ 200N, effectively buffering external force impact, preventing optical fiber breakage caused by tension during installation or driving; Polyurethane outer sheath: high elasticity, wear resistance and bending fatigue resistance, bending life > 50000 times, can resist repeated winding, vibration and chemical medium (such as coolant, lubricating oil) erosion.

[0031] 4. Arc-shaped holes and connecting cavities are provided, the heat generated by the super flexible annealed bare copper conductor during operation can enter the arc-shaped holes, and the arc-shaped holes are in communication with the outside, and the arc-shaped holes and the connecting cavities further increase the heat dissipation surface, so that the cable has better heat dissipation effect; at the same time, when laying is needed, the super flexible annealed bare copper conductor can be taken out by only using a blade to cut the arc-shaped hole corresponding to the super flexible annealed bare copper conductor to be taken out.

[0032] 5. The arc-shaped holes can also play a role in buffering impact, making the cable have better impact resistance, and the arc-shaped holes and the connecting cavities can reduce the amount of outer sheath material, and the cost is lower.

[0033] In summary, through structural innovation and material reconstruction, the present application realizes a comprehensive breakthrough in the overall diameter, heat dissipation, mechanical strength and environmental adaptability of the optical-electric composite cable, especially suitable for use in the three-electric systems (battery, motor, electric control) of new energy vehicles, vehicle information entertainment systems and advanced driver assistance systems (ADAS) in high-density wiring, high heat power and strong vibration environment, with significant reliability improvement and integration advantage. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 The cross-sectional view of embodiment 1 of the present application.

[0035] Figure 2A cross-sectional view of the optical unit of the present application in Example 3.

[0036] Figure 3 A cross-sectional view of the optical unit of the present application in Example 3 after removing the super flexible annealed bare copper conductor.

[0037] Figure 4 A cross-sectional view of the optical unit of the present application in Example 4.

[0038] Figure 5 A cross-sectional view of the optical unit of the present application in Example 5 after removing the super flexible annealed bare copper conductor.

[0039] In the figure, the corresponding figure names of the reference numerals are as follows: 1. tight packed optical fiber, 11. high temperature resistant optical fiber, 12. tight packing layer, 2. aramid fiber reinforced layer, 3. super flexible annealed bare copper conductor, 4. outer sheath, 41. outer sheath main body, 42. arc-shaped hole, 43. connecting cavity, 44. accommodating cavity, 441. first accommodating cavity, 442. second accommodating cavity, 5. connecting neck. DETAILED DESCRIPTION

[0040] Example 1: As Figure 1 A vehicle optical and electrical composite cable, comprising two optical units and a connecting neck 5 connected between the two optical units, the connecting neck 5 being used for structural transition and stress relief.

[0041] Each of the optical units comprises a tight packed optical fiber 1, an aramid fiber reinforced layer 2 wrapped around the outer periphery of the tight packed optical fiber 1, and an outer sheath 4 located at the outermost layer.

[0042] The outer sheath 4 comprises an outer sheath main body 41 and nineteen super flexible annealed bare copper conductors 3, the outer sheath main body 41 wrapping the aramid fiber reinforced layer 2, and the nineteen super flexible annealed bare copper conductors 3 being evenly located in the outer sheath main body 41 in a circumferential array with the axis of the tight packed optical fiber 1 as the center, and realizing an integrated heat dissipation structure with the outer sheath 4.

[0043] The tight packed optical fiber 1 comprises a high temperature resistant optical fiber 11 and a tight packing layer 12 of polytetrafluoroethylene material wrapped around the high temperature resistant optical fiber 11.

[0044] The high temperature resistant optical fiber 11 adopts a multi-mode optical fiber (such as OM3 / OM4 grade) with bending resistance and low attenuation characteristics, and its working temperature range can reach -60℃-150℃. The tight packing layer 12 is wrapped around the surface of the high temperature resistant optical fiber 11 through an extrusion coating process, with a thickness controlled at 0.3-0.35mm, ensuring that it has excellent high temperature resistance, chemical corrosion resistance and micro-bending resistance.

[0045] The aramid fiber reinforced layer 2 is wrapped around the outside of the high-temperature-resistant tight-wrapped optical fiber 1 in a longitudinal wrapping manner, uses multiple aramid yarns, and provides a tensile strength of not less than 200 N to effectively resist tensile stress during installation and use.

[0046] The outer sheath body 41 is made of thermoplastic polyurethane material and has high elasticity, oil resistance and fatigue resistance. The outer diameter of the optical unit is preferably 2.0±0.1mm, and is suitable for Mini-FAKRA, MATE-AX and other miniature vehicle connectors.

[0047] Embodiment 2: A method for preparing a vehicle optical and electrical composite cable, for preparing the vehicle optical and electrical composite cable of embodiment 1, comprising the following steps: Step 01: Tight wrapping of optical fiber; the high-temperature-resistant optical fiber is tightly wrapped by a polytetrafluoroethylene extruder, and the extrusion temperature is controlled at 250-380℃, to form a uniform and defect-free tight-wrapped optical fiber 1; Step 02: Aramid wrapping; the aramid fiber is wrapped around the outer surface of the tight-wrapped optical fiber 1 by a high-speed wrapping machine to form the aramid fiber reinforced layer 2; Step 03: Arrangement of conductor and co-extrusion of sheath; the super-flexible annealed bare copper conductor 3 is positioned through a guide die, and then co-extruded with thermoplastic polyurethane outside the aramid fiber reinforced layer 2 to form the outer sheath 4. The die temperature is controlled at 170-185℃ during extrusion, and the pressure is maintained at 12-15MPa, to ensure accurate positioning of the conductor and dense combination with the outer sheath body 41; Step 04: Cooling and winding; segmented cooling is performed by a water cooling tank, and the cooling rate is controlled to prevent structural deformation, and finally the cable is wound by a tension control winding system.

[0048] Embodiment 3: As Figure 2 and Figure 3 A vehicle optical and electrical composite cable, comprising two optical units and a connecting neck 5 connected between the two optical units, the connecting neck 5 being used for structural transition and stress relief.

[0049] Each of the optical units comprises a tight-wrapped optical fiber 1, an aramid fiber reinforced layer 2 wrapped around the outer periphery of the tight-wrapped optical fiber 1, and an outer sheath 4 located at the outermost layer.

[0050] The outer sheath 4 comprises an outer sheath body 41 and twenty super-flexible annealed bare copper conductors 3, and the outer sheath body 41 wraps the aramid fiber reinforced layer 2.

[0051] The outer sheath body 41 is internally formed with ten conductor accommodating cavity groups with the axis of the tight-fitting optical fiber 1 as the center, each of the conductor accommodating cavity groups comprises two accommodating cavities 44, an arc-shaped hole 42 and a connecting cavity 43, the two accommodating cavities are respectively a first accommodating cavity 441 and a second accommodating cavity 442, the first accommodating cavity 441 is in communication with one end of the arc-shaped hole 42, the second accommodating cavity 442 is located in the region formed by the connecting line of the two end portions of the arc-shaped hole 42 and the axis of the tight-fitting optical fiber 1, and the second accommodating cavity 442 is in communication with the arc-shaped hole 42 through the connecting cavity 43, one of the super-soft annealed bare copper conductors 3 is arranged in each of the accommodating cavities 44, and the super-soft annealed bare copper conductor 3 is in close contact with the inner wall of the accommodating cavity 44.

[0052] The width of the connecting cavity 43 is smaller than the diameter of the accommodating cavity 44, and the width of the arc-shaped hole 42 is smaller than the diameter of the accommodating cavity 44.

[0053] The tight-fitting optical fiber 1 comprises a high-temperature-resistant optical fiber 11 and a tight-fitting layer 12 made of polytetrafluoroethylene material covering the high-temperature-resistant optical fiber 11.

[0054] The high-temperature-resistant optical fiber 11 adopts a multimode optical fiber (such as OM3 / OM4 grade) with bending resistance and low attenuation characteristics, and the working temperature range can reach-60℃-150℃. The tight-fitting layer 12 is coated on the surface of the high-temperature-resistant optical fiber by an extrusion coating process, and the thickness is controlled to be 0.3-0.35mm, so as to ensure that it has excellent high-temperature resistance, chemical corrosion resistance and micro-bending resistance.

[0055] The aramid fiber reinforced layer 2 is wrapped around the outside of the tight-fitting optical fiber 1 in a longitudinal wrapping manner, adopts a plurality of aramid yarns, and provides a tensile strength of not less than 200N, which effectively resists the tensile stress in the installation and use process.

[0056] The outer sheath body 41 is made of thermoplastic polyurethane material, and has high elasticity, oil resistance and fatigue resistance.

[0057] The outer diameter of the optical unit is preferably 2.0±0.1mm, and is suitable for Mini-FAKRA, MATE-AX and other miniature vehicle connectors.

[0058] Embodiment 4: as Figure 4 and Figure 5 A vehicle optical and electrical composite cable comprises two optical units and a connecting neck 5 connected between the two optical units, and the connecting neck 5 is used for structural transition and stress relief.

[0059] Each of the optical units comprises a tight-fitting optical fiber 1, an aramid fiber reinforced layer 2 covering the outer periphery of the tight-fitting optical fiber 1, and an outer sheath 4 located at the outermost layer.

[0060] The outer sheath 4 comprises an outer sheath body 41 and twenty super-soft annealed bare copper conductors 3, and the outer sheath body 41 covers the aramid fiber reinforced layer 2.

[0061] The outer sheath body 41 internally forms ten conductor cavity groups with the axis of the tight-packaged optical fiber 1 as the center, each of the conductor cavity groups comprises two cavities 44, an arc-shaped hole 42 and a connecting cavity 43, the two cavities 44 are a first cavity 441 and a second cavity 442 respectively, the first cavity 441 and the second cavity 442 are located in the region formed by the connecting line of the two end portions of the arc-shaped hole 42 and the axis of the tight-packaged optical fiber 1, and the first cavity 441 and the second cavity 442 communicate with the arc-shaped hole 42 through the connecting cavity 43, one of the super-soft annealed bare copper conductors 3 is arranged in each of the cavities 44, and the super-soft annealed bare copper conductor 3 is in close contact with the inner wall of the cavity 44.

[0062] The width of the connecting cavity 43 is smaller than the diameter of the cavity 44, and the width of the arc-shaped hole 42 is smaller than the diameter of the cavity 44.

[0063] The arc-shaped hole is a circular arc-shaped hole, the center of the circular arc-shaped hole coincides with the axis of the tight-packaged optical fiber 1, and the first cavity and the second cavity are symmetrically arranged about the symmetry axis of the circular arc-shaped hole. By arranging the circular arc-shaped hole and arranging the first cavity and the second cavity symmetrically about the symmetry axis of the circular arc-shaped hole, the outer sheath body 41 can be uniformly stressed in all directions in the radial direction, and the stability of the vehicle optical fiber composite cable can be improved.

[0064] The tight-packaged optical fiber 1 comprises a high-temperature-resistant optical fiber 11 and a tight-packaging layer 12 made of polytetrafluoroethylene material arranged on the high-temperature-resistant optical fiber 11.

[0065] The high-temperature-resistant optical fiber 11 adopts a multimode optical fiber (such as OM3 / OM4 grade) with bending resistance and low attenuation characteristics, and the working temperature range can reach-60℃-150℃. The tight-packaging layer 12 is coated on the surface of the high-temperature-resistant optical fiber by an extrusion coating process, and the thickness is controlled within 0.3-0.35mm, so as to ensure that it has excellent high-temperature resistance, chemical corrosion resistance and micro-bending resistance.

[0066] The aramid fiber reinforced layer 2 is wrapped around the outside of the tight-packaged optical fiber 1 in a longitudinal wrapping manner, adopts a plurality of aramid yarns, and provides a tensile strength of not less than 200N, which effectively resists the tensile stress in the installation and use process.

[0067] The outer sheath body 41 is made of thermoplastic polyurethane material, and has high elasticity, oil resistance and fatigue resistance.

[0068] The outer diameter of the optical unit is preferably 2.0±0.1mm, which is suitable for micro-vehicle connectors such as Mini-FAKRA and MATE-AX.

[0069] The ultra-flexible annealed bare copper conductor 3 described above can also be replaced by a copper conductor with an insulating sleeve.

[0070] Example 4: A new energy vehicle comprising the vehicle-mounted optical-electric composite cable described in any of the above embodiments. In addition, the new energy vehicle also includes structures such as a vehicle frame, which, since they do not involve the core inventive points of this invention, will not be described in detail here; conventional designs can be referenced.

[0071] The present invention has the following beneficial effects: 1. Polytetrafluoroethylene (PTFE, commonly known as Teflon) is used as the tight cladding layer of the optical fiber. This material has excellent high-temperature resistance, chemical stability, and low friction characteristics. The tight cladding structure provides reliable mechanical protection and signal isolation for the optical fiber, enabling stable operation within a temperature range of -60℃ to +200℃. It effectively resists the humid and hot environment, oil corrosion, and electromagnetic interference encountered during vehicle operation, ensuring low-loss and high-bandwidth transmission performance of optical signals in complex vehicle environments. It is particularly suitable for high-speed data transmission scenarios such as vehicle networks, LiDAR, and cameras.

[0072] 2. Conductor-Uniformly Distributed Heat Dissipation Integrated Structure Design Innovatively, multiple ultra-flexible annealed bare copper conductors are uniformly arranged in a circumferential array within a polyurethane (TPU) outer sheath, achieving synergistic optimization of structure and heat dissipation: Miniaturization of outer diameter: Compared to traditional stranded structures, this design "divides the conductor into smaller parts," integrating the power transmission unit into the cable body without changing the original outer diameter of the optical cable, successfully achieving optoelectronic composite. This structure significantly improves space utilization efficiency and can be adapted to miniaturized connectors (such as MATE-AX, Mini-FAKRA, etc.), meeting the requirements of high integration and narrow wiring in new energy vehicle electronic modules.

[0073] Significantly improved heat dissipation performance: The conductor is in direct contact with the polyurethane sheath, increasing the total effective heat dissipation surface area by 335.8% compared to the traditional stranded structure, eliminating the thermal barrier formed by air gaps between conductors. The polyurethane material possesses excellent thermal conductivity (≥0.2 W / m·K), rapidly dissipating heat generated during current transmission to the external environment and preventing excessive localized temperature rise. Experiments show that this structure reduces temperature rise by more than 40% under rated current, significantly delaying insulation aging and improving long-term current-carrying reliability.

[0074] 3. Triple protection system against mechanical stress To address the harsh operating conditions of new energy vehicles, such as frequent vibration, bending, and pulling, a multi-layered mechanical protection system is constructed: Teflon tight cladding layer: provides the first heavy protection, temperature resistance ≥ 150℃, ensures that the optical fiber still maintains good mechanical strength and signal integrity in high temperature environment; Aramid fiber reinforced layer: wrapped around the periphery of the optical fiber unit, providing a tensile strength of ≥ 200N, effectively buffering external force impact, preventing optical fiber breakage caused by tension during installation or driving; Polyurethane outer sheath: high elasticity, wear resistance and bending fatigue resistance, bending life > 50000 times, can resist repeated winding, vibration and chemical medium (such as coolant, lubricating oil) erosion.

[0075] 4. The arc-shaped hole and the connecting cavity are provided, the heat generated by the ultra-soft annealed bare copper conductor during work can enter the arc-shaped hole, the arc-shaped hole is communicated with the outside, and the arc-shaped hole and the connecting cavity further increase the heat dissipation surface, so that the cable has better heat dissipation effect; at the same time, when the ultra-soft annealed bare copper conductor needs to be taken alone, the ultra-soft annealed bare copper conductor can be taken out by only cutting the arc-shaped hole corresponding to the ultra-soft annealed bare copper conductor to be taken.

[0076] 5. The arc-shaped hole can also play a role in buffering impact, so that the cable has better impact resistance, and the arc-shaped hole and the connecting cavity can reduce the amount of outer sheath material, and the cost is lower.

[0077] In summary, through structural innovation and material reconstruction, the present application realizes a comprehensive breakthrough in the overall diameter, heat dissipation, mechanical strength and environmental adaptability of the photoelectric composite cable, especially in the new energy automobile three-electricity system (battery, motor, electric control), vehicle information entertainment system and advanced driving assistance system (ADAS) in high-density wiring, high heat power and strong vibration environment, which has significant reliability improvement and integration advantage.

[0078] The above embodiments are only preferred technical solutions of the present application, and should not be regarded as a limitation of the present application. The protection scope of the present application should be based on the technical solutions claimed in the claims, including the equivalent replacement solutions of the technical features claimed in the claims. That is, within this range, equivalent replacement improvements are also within the protection scope of the present application.

Claims

1. A vehicle optical fiber cable, characterized by comprising: The utility model relates to a kind of optical cable, including: Two optical units and connecting neck (5) connected between two optical units; Each optical unit includes tight optical fiber (1), aramid fiber reinforced layer (2) coated in the outer periphery of tight optical fiber (1) and outer sheath (4) located outermost layer; Wherein, the outer sheath (4) includes outer sheath main body (41) and at least three super-soft annealed bare copper conductor (3), the outer sheath main body (41) is coated aramid fiber reinforced layer (2), and the at least three super-soft annealed bare copper conductor (3) is with the axis of tight optical fiber (1) as the center of circle and is uniformly located in the outer sheath main body (41) in the way of circumferential array.

2. The light-electricity composite cable for vehicle according to claim 1, wherein The inner part of the outer sheath main body (41) forms a plurality of conductor cavity groups with the axis of tight optical fiber (1) as the center of circle, each conductor cavity group includes two cavities (44) and an arc-shaped hole (42);Two cavities (44) are communicated with the arc-shaped hole (42), and one of the cavities (44) is provided with one of the super-soft annealed bare copper conductor (3).

3. The light-electricity composite cable for vehicle according to claim 2, wherein Each conductor cavity group includes first cavity (441), second cavity (442), arc-shaped hole (42) and connecting cavity (43), the first cavity (441) is communicated with one end of the arc-shaped hole (42), the second cavity (442) is located in the region formed by the two ends of the arc-shaped hole (42) and the axis of tight optical fiber (1), and the second cavity (442) is communicated with the arc-shaped hole (42) through the connecting cavity (43).

4. The light-electricity composite cable for vehicle according to claim 3, wherein The width of the connecting cavity (43) is less than the diameter of the cavity (44), the width of the arc-shaped hole (42) is less than the diameter of the cavity (44), and the super-soft annealed bare copper conductor (3) is closely attached to the inner wall of the cavity (44).

5. The light-electricity composite cable for vehicle according to claim 2, wherein Each conductor cavity group includes first cavity (441), second cavity (442), arc-shaped hole (42) and connecting cavity (43), the first cavity (441) and the second cavity (442) are located in the region formed by the two ends of the arc-shaped hole (42) and the axis of tight optical fiber (1), and the first cavity (441) and the second cavity (442) are communicated with the arc-shaped hole (42) through the connecting cavity (43).

6. The light-electricity composite cable for vehicle according to claim 5, wherein The width of the connecting cavity (43) is less than the diameter of the cavity (44), the width of the arc-shaped hole (42) is less than the diameter of the cavity (44), and the super-soft annealed bare copper conductor (3) is closely attached to the inner wall of the cavity (44).

7. The light-electricity composite cable for vehicle according to claim 5, wherein The arc-shaped hole (42) is a circular arc-shaped hole, the center of the circular arc-shaped hole coincides with the axis of tight optical fiber (1), and the first cavity (441) and the second cavity (442) are symmetrically arranged about the symmetry axis of the circular arc-shaped hole.

8. The light-electricity composite cable for vehicle according to claim 1, wherein The tight optical fiber (1) includes high-temperature resistant optical fiber (11) and tight layer (12) of polytetrafluoroethylene material coated on the high-temperature resistant optical fiber (11).

9. The light-electricity composite cable for vehicle according to claim 1, wherein The outer sheath main body (41) is a thermoplastic polyurethane material.

10. A new energy vehicle, characterized in that, A vehicle optical fiber cable comprising the optical fiber composite cable according to any one of claims 1 to 9.

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