Aluminum alloy wire, process for producing the same, and automobile charging pile

Abstract

The application discloses an aluminum alloy wire, a preparation process thereof and an automobile charging pile, and relates to the technical field of wires, wherein the aluminum alloy wire comprises a wire core, and the components of the wire core comprise the following components in percentage by weight: Mg: 0.9% to 1.1%, Si: 0.45% to 0.55%, Cu: 0.1% to 0.2% and Ti: 0.03% to 0.04%; the balance is Al and inevitable impurities, and the impurity content is less than or equal to 0.4%. The technical scheme provided by the application aims to reduce the cost of the wire and improve the performance stability of the wire.

Description

Technical Field

[0001] This invention relates to the field of conductor technology, and in particular to an aluminum alloy wire, its manufacturing process, and an electric vehicle charging station. Background Technology

[0002] Electromagnetic compatibility (EMC) refers to the performance parameters of an electronic device that neither interferes with nor is affected by other devices. It is one of the important indicators of product quality.

[0003] To meet the requirements of high current transmission (e.g., 300A-500A) and electromagnetic compatibility, existing fast charging harnesses for new energy vehicles generally use copper conductors with metal shielding layers, such as copper mesh shielding layers or aluminum foil shielding layers. However, this approach has the following drawbacks: high processing and assembly costs; the aluminum foil of the shielding layer is prone to breakage due to bending, and the copper mesh is prone to oxidation, leading to a decrease in electromagnetic compatibility performance and affecting the stability of the wire's electromagnetic compatibility. Summary of the Invention

[0004] The main objective of this invention is to propose an aluminum alloy wire, its manufacturing process, and an electric vehicle charging station, aiming to reduce wire costs and improve wire performance stability.

[0005] To achieve the above objectives, the present invention provides an aluminum alloy wire comprising a wire core, wherein the wire core comprises the following components by weight percentage: Mg: 0.9% to 1.1%; Si: 0.45% to 0.55%; Cu: 0.1% to 0.2%; Ti: 0.03% to 0.04%; The balance is Al and unavoidable impurities, wherein the impurity content is ≤0.4%.

[0006] In one embodiment, the surface of the wire core is provided with a radiation-reducing spiral groove.

[0007] In one embodiment, the depth of the radiation-reducing spiral groove ranges from 0.3 mm to 0.5 mm; and / or, The pitch of the radiation-reducing spiral groove ranges from 5 mm to 7 mm.

[0008] In one embodiment, the aluminum alloy wire further includes an insulation layer covering the outside of the wire core, wherein the insulation layer contains 2% to 3% by weight of modified cross-linked polyethylene with nano-calcium carbonate.

[0009] In one embodiment, the aluminum alloy wire further includes a wear-resistant protective layer, which covers the outside of the insulating layer.

[0010] This invention also proposes a process for preparing aluminum alloy wire, comprising the following steps: The raw material weighing step; wherein the raw material comprises the following components by weight percentage: Mg: 0.9% to 1.1%, Si: 0.45% to 0.55%, Cu: 0.1% to 0.2%, Ti: 0.03% to 0.04%, with the balance being Al and unavoidable impurities, wherein the impurity content is ≤0.4%; Raw material processing steps: After melting and heat preservation of the raw material, an aluminum alloy rod is made, and the aluminum alloy rod is drawn and annealed to obtain the wire core.

[0011] In one embodiment, after the raw material processing step, the preparation process of the aluminum alloy wire further includes: Radiation-reducing spiral grooves are machined on the surface of the wire core using a forming mold.

[0012] In one embodiment, after the raw material processing step, the preparation process of the aluminum alloy wire further includes: In the insulation coating step, modified cross-linked polyethylene with 2% to 3% nano-calcium carbonate added is heated to melt and then coated onto the outside of the wire core; segmented water cooling is used to cool it to room temperature.

[0013] In one embodiment, after the insulation layer coating step, the manufacturing process of the aluminum alloy wire further includes: The wear-resistant protective layer coating step involves heating PEEK material to a molten state and then coating it over the insulation layer.

[0014] The present invention also proposes a car charging pile, comprising the aforementioned aluminum alloy wire.

[0015] This technical solution employs a specific ratio of Mg, Si, Cu, Ti, and Al, with each element working synergistically. The Mg2Si phase formed by Mg and Si significantly enhances the strength and toughness of the wire core, while Cu further strengthens the alloy through age hardening. Ti refines the grain size, improving the overall mechanical properties of the wire core. Simultaneously, the impurity content is strictly controlled to below 0.4%, preventing impurities from adversely affecting the alloy's performance. This results in a wire core with both excellent conductivity and mechanical strength. Compared to traditional shielding structures, the wire in this application does not require a separate shielding layer, meeting the electromagnetic compatibility and temperature rise requirements of electric vehicle charging piles, thus reducing manufacturing and usage costs. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a cross-sectional schematic diagram of an embodiment of the aluminum alloy wire provided by the present invention; Figure 2 for Figure 1 Schematic diagram of the structure of the center core; Figure 3 This is a schematic diagram illustrating the steps of an embodiment of the aluminum alloy wire preparation process provided by the present invention.

[0018] Explanation of icon numbers: 1. Core wire; 2. Radiation-reducing spiral groove; 3. Insulation layer; 4. Wear-resistant protective layer.

[0019] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, and back), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0023] Electromagnetic compatibility (EMC) refers to the performance parameters of an electronic device that neither interferes with nor is affected by other devices. It is one of the important indicators of product quality.

[0024] To meet the requirements of high current transmission (e.g., 300A-500A) and electromagnetic compatibility, existing fast charging harnesses for new energy vehicles generally use copper conductors with metal shielding layers, such as copper mesh shielding layers or aluminum foil shielding layers. However, this approach has the following drawbacks: high processing and assembly costs; the aluminum foil of the shielding layer is prone to breakage due to bending, and the copper mesh is prone to oxidation, leading to a decrease in electromagnetic compatibility performance and affecting the stability of the wire's electromagnetic compatibility.

[0025] Based on the above problems, this invention proposes an aluminum alloy wire, its preparation process, and an electric vehicle charging pile.

[0026] Please see Figure 1 and Figure 2 In one embodiment of the present invention, the aluminum alloy wire includes a wire core 1, the composition of which, by weight percentage, includes the following components: Mg: 0.9% to 1.1%, Si: 0.45% to 0.55%, Cu: 0.1% to 0.2% and Ti: 0.03% to 0.04%; the balance being Al and unavoidable impurities, wherein the impurity content is ≤0.4%.

[0027] This technical solution employs a specific ratio of Mg, Si, Cu, Ti, and Al, with each element working synergistically. The Mg2Si phase formed by Mg and Si significantly enhances the strength and toughness of the wire core 1. Cu further enhances the age-hardening effect of the alloy, while Ti refines the grains, improving the overall mechanical properties of the wire core 1. Simultaneously, the impurity content is strictly controlled to within 0.4%, avoiding any adverse effects on the alloy's performance. This results in wire core 1 possessing both excellent conductivity and mechanical strength. Compared to traditional shielding structures, the wire in this application does not require a separate shielding layer, meeting the electromagnetic compatibility and temperature rise requirements of electric vehicle charging piles, thus reducing manufacturing and usage costs.

[0028] In the specific implementation process, a high-precision electronic balance can be used for accurate proportioning of raw materials. There are no restrictions on the specific weight. For example, when preparing 100kg of wire core 1, weigh out 0.9kg of Mg, 0.45kg of Si, 0.1kg of Cu, 0.03kg of Ti, and 98.12kg of Al, with the remainder being the total mass of various impurities. Another example is when preparing 100kg of wire core 1, weigh out 1.1kg of Mg, 0.55kg of Si, 0.2kg of Cu, 0.04kg of Ti, and 97.71kg of Al, with the remainder being the total mass of various impurities. Yet another example is when preparing 100kg of wire core 1, weigh out 1.0kg of Mg, 0.5kg of Si, 0.15kg of Cu, 0.03kg of Ti, and 97.95kg of Al, with the remainder being the total mass of various impurities. Impurities can include, for example, iron, manganese, zinc, nickel, lead, and tin.

[0029] In one embodiment, the surface of the wire core 1 is provided with a radiation-reducing spiral groove 2.

[0030] This technical solution employs a structure with a radiation-reducing spiral groove 2 on the surface of the wire core 1. The radiation-reducing spiral groove 2 constitutes a microscopic resonant cavity structure. Electromagnetic waves will undergo multiple reflections and scatterings inside the groove, significantly extending their propagation path within the material and increasing the probability of absorption. At the same time, the spiral groove structure can also increase the surface area of ​​the wire core 1, improve heat dissipation efficiency, and avoid affecting the performance and service life of the wire due to excessively high local temperatures.

[0031] In the specific implementation process, a CNC milling machine or a mold can be used to process the anti-radiation spiral groove 2 on the surface of the drawn wire core 1. The specific shape parameters of the anti-radiation spiral groove 2 are not limited. For example, the pitch can be 3mm, 5mm, 7mm, 10mm or 20mm, the depth can be 0.2mm, 0.3mm, 0.5mm, 1.6mm or 3mm, the width can be 1mm or 3mm, and the cross-sectional shape can be rectangular or arc-shaped.

[0032] In one embodiment, the depth of the anti-radiation spiral groove 2 ranges from 0.3 mm to 0.5 mm; and / or, the pitch of the anti-radiation spiral groove 2 ranges from 5 mm to 7 mm.

[0033] This technical solution employs a radiation-reducing spiral groove 2 with the aforementioned depth and pitch range. When the groove depth is controlled between 0.3mm and 0.5mm, it can ensure the dispersion effect of the electromagnetic field without excessively weakening the mechanical strength of the wire core 1. When the pitch is controlled between 5mm and 7mm, the electromagnetic field dispersion effect is good, while not increasing the processing difficulty and cost excessively.

[0034] In the specific implementation process, the parameters can be adjusted according to the actual diameter of the wire core 1 during processing. For example, for wire core 1 with a larger diameter, a groove depth of 0.5mm and a pitch of 7mm can be selected. For wire core 1 with a smaller diameter, a groove depth of 0.3mm and a pitch of 5mm can be selected to balance the radiation reduction effect and the performance of wire core 1.

[0035] In one embodiment, the aluminum alloy wire further includes an insulation layer 3, which covers the outside of the wire core 1, and the insulation layer 3 contains 2% to 3% by weight of modified cross-linked polyethylene with nano-calcium carbonate.

[0036] This technical solution adds 2% to 3% by mass of nano-calcium carbonate as the insulation layer 3 material to cross-linked polyethylene. The nano-sized particles of nano-calcium carbonate can be uniformly dispersed in the cross-linked polyethylene matrix, which improves the mechanical strength and heat resistance of the insulation layer 3, while enhancing the dielectric properties of the insulation layer 3, effectively preventing the leakage of current from the core 1, ensuring electrical safety, and the structure covering the outside of the core 1 can also provide good protection for the core 1.

[0037] In the specific implementation process, nano-calcium carbonate and cross-linked polyethylene particles can be thoroughly mixed first, and then melted by heating in an extruder. The mixture can then be coated onto the outside of the preheated wire core 1 using an extrusion coating process. For example, under the condition that the extruder temperature is set to 180°C to 200°C, the coating of the insulation layer 3 can be completed, so that the insulation layer 3 has a uniform thickness and is tightly adhered.

[0038] In one embodiment, the aluminum alloy wire further includes a wear-resistant protective layer 4, which covers the outside of the insulating layer 3.

[0039] This technical solution employs a structure in which a wear-resistant protective layer 4 is wrapped around the outside of the insulation layer 3, allowing the wear-resistant protective layer 4 to directly withstand external friction and impact, preventing the insulation layer 3 from being damaged due to wear, thereby extending the overall service life of the aluminum alloy wire. At the same time, the multi-layered structure can further improve the protective performance of the wire and reduce the impact of the external environment on the wire core 1.

[0040] In the specific implementation process, the wear-resistant protective layer 4 can be made of plastic material and is put on the outside of the insulation layer 3 by hot extrusion or heat shrink wrapping. For example, a pre-made plastic heat shrink tube is put on the outside of the insulation layer 3, and then the heat shrink tube is shrunk and tightly wrapped on the insulation layer 3 by heating with a hot air gun. The operation is simple and the protective effect is good.

[0041] Please see Figure 3 This invention also proposes a process for preparing aluminum alloy wire, the specific structure of which refers to the above embodiments. Since the preparation process of the aluminum alloy wire adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here. The preparation process of the aluminum alloy wire includes the following steps: S100: Weighing raw materials; wherein the raw materials comprise the following components by weight percentage: Mg: 0.9% to 1.1%, Si: 0.45% to 0.55%, Cu: 0.1% to 0.2%, Ti: 0.03% to 0.04%, with the balance being Al and unavoidable impurities, wherein the impurity content is ≤0.4%; S200: Raw material processing steps; after melting and heat preservation of the raw material, an aluminum alloy rod is made, and the aluminum alloy rod is drawn and annealed to obtain the wire core 1.

[0042] This technical solution first weighs the raw materials that meet the above-mentioned component ratios, laying the foundation for the subsequent preparation of high-performance aluminum alloy wire core 1. The precise raw material ratio ensures that each element can fully exert its synergistic effect, avoiding the mechanical and electrical properties of wire core 1 failing to meet the standards due to deviations in the raw material ratio. Through the melting and heat preservation process, the raw materials can be fully mixed and reacted to form a uniform alloy structure. The drawing process can process the aluminum alloy rod to the required diameter of wire core 1. The annealing treatment can eliminate the internal stress generated during the drawing process, improve the plasticity and toughness of wire core 1, and make the performance of wire core 1 more stable.

[0043] In the specific implementation process, the amount of each raw material can be calculated according to the amount of wire core 1 to be prepared, and the specific amount is referred to in Examples 1 to 3 above. During melting, a medium frequency induction furnace can be used, and the heating temperature is controlled at 710℃ to 740℃, and the temperature is held for 2 to 3 hours to ensure that the raw materials are fully fused. During drawing, a multi-pass continuous drawing process is adopted, and the deformation amount of each drawing is controlled at 10% to 25%. After drawing, the wire core 1 is placed in an annealing furnace and held at 350℃ to 400℃ for 1 to 2 hours to complete the annealing treatment.

[0044] In one embodiment, after the raw material processing step, the preparation process of the aluminum alloy wire further includes: S300: Radiation-reducing spiral grooves 2 are machined on the surface of the wire core 1 using a forming mold.

[0045] This technical solution employs a step of processing anti-radiation spiral grooves 2 on the surface of the wire core 1 using a forming mold after the raw material processing step. By utilizing the precise shaping of the forming mold, anti-radiation spiral grooves 2 with specifications meeting the requirements can be processed quickly and in batches on the surface of the wire core 1 after drawing and annealing, thereby improving processing efficiency and product consistency.

[0046] In the specific implementation process, a forming mold that matches the diameter and groove parameters of the wire core 1 can be selected. The specific type of mold is not limited. For example, it can be a stamping mold or a cold drawing mold.

[0047] In one embodiment, after the raw material processing step, the preparation process of the aluminum alloy wire further includes: S400: Insulation layer 3 coating step, modified cross-linked polyethylene with 2% to 3% nano calcium carbonate added is heated to melt and then coated on the outside of the wire core 1; segmented water cooling is used to cool to room temperature.

[0048] In this technical solution, the modified cross-linked polyethylene that is heated and melted can be tightly bonded to the outside of the core 1 to form a uniform insulation layer 3. The segmented water cooling method can gradually cool the insulation layer 3, avoiding cracks or internal stress caused by excessive cooling, and improving the stability and protective performance of the insulation layer 3.

[0049] In the specific implementation process, the modified cross-linked polyethylene with added nano-calcium carbonate is placed in an extruder and heated to 190°C to 210°C to melt it. Then, the molten material is wrapped around the wire core 1, which moves at a speed of 5m / min to 6m / min, through the extruder head. Then, it passes through two water cooling tanks with water temperatures of 60°C to 70°C and 30°C to 40°C in sequence, so that the insulation layer 3 is gradually cooled to room temperature to ensure the molding quality of the insulation layer 3.

[0050] In one embodiment, after the insulation layer 3 coating step, the manufacturing process of the aluminum alloy wire further includes: S500: The wear-resistant protective layer 4 coating step involves heating the PEEK material to a melt and then coating it over the insulation layer 3.

[0051] This technical solution employs a step of heating PEEK material to molten state and then coating it onto the outside of the insulation layer 3 after the insulation layer 3 coating step. By utilizing the excellent wear resistance, heat resistance, and chemical stability of PEEK material, reliable protection is provided for the insulation layer 3, further extending the service life of the aluminum alloy wire.

[0052] In the specific implementation process, an extrusion molding process is adopted. The PEEK material is placed in a special high-temperature extruder and heated to 350°C to 390°C to melt it. Then, the molten PEEK material is coated on the outside of the insulation layer 3 at a speed of 5m / min to 6m / min. After cooling, a wear-resistant protective layer 4 is formed.

[0053] The present invention also proposes a car charging pile, comprising the aforementioned aluminum alloy wire. The specific structure of the aluminum alloy wire is as described in the above embodiments. Since the car charging pile adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0054] This technical solution utilizes the aforementioned aluminum alloy wire in the car charging pile, leveraging the excellent conductivity, mechanical strength, radiation reduction, and wear resistance of the aluminum alloy wire to provide a stable and reliable carrier for power transmission in the car charging pile. Simultaneously, it reduces electromagnetic radiation during charging pile use, improves the safety and lifespan of the charging pile, and meets the requirements of long-term, high-load use of the car charging pile.

[0055] The technical solution of the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be understood that the following embodiments are only used to explain the present invention and are not intended to limit the present invention.

[0056] Example 1 The aluminum alloy wire preparation process in this embodiment is used to prepare unshielded aluminum wire suitable for 400A current. It requires the preparation of 100kg of wire core 1 and includes the following steps: Raw materials are weighed according to the following mass percentages: Al 97.95%, Mg 1.0%, Si 0.5%, Cu 0.15%, Ti 0.03%, with the remainder being the total mass of various impurities; smelting is carried out at 730℃, held for 2.5h, and slag is removed; a 20mm diameter aluminum rod is produced by continuous casting-rolling; it is then drawn three times (each time with a deformation of 22%) to a diameter of 10mm, and annealed at 400℃ for 1.2h to obtain the conductor core. Modified cross-linked polyethylene with 2.5% nano-calcium carbonate is heated to 190℃ and melted; it is then extruded through a machine at a linear speed of 6m / min to coat the conductor core, controlling the thickness to 1.8mm; segmented water cooling (first segment 70℃, second segment 25℃) is used to cool to room temperature to avoid internal stress. Polyetheretherketone (PEEK) material is heated to 390℃ and melted; it is then extruded at a linear speed of 5 m / min to coat the outer layer of insulation 3, with a thickness controlled at 1.0 mm; and then naturally cooled to room temperature to obtain the finished unshielded aluminum wire.

[0057] Example 2 The preparation process of the aluminum alloy wire in this embodiment is similar to that in Embodiment 1, except that: After three drawing operations (each with a deformation of 22%) to a diameter of 10 mm and annealing at 400°C for 1.2 h, a spiral groove (0.4 mm deep, 6 mm pitch) is machined on the surface of the aluminum wire using a forming mold to obtain the conductor core.

[0058] Examples 3 to 4 and Comparative Example 1 differ from Example 1 in the following ways, as shown in Table 1. Comparative Example 1 is an existing aluminum core + copper shielded wire harness.

[0059] Table 1. Parameter settings for Examples 1 to 4 and Comparative Example 1

[0060] Performance testing The wire products of Examples 1 to 4 and Comparative Example 1 were subjected to performance tests, and the test methods are as follows: (1) Mechanical strength: Characterized by tensile strength test, the tensile strength is determined in accordance with GB / T 1040 "Determination of tensile properties of plastics"; (2) Conductivity: The conductivity was characterized by the four-probe method. The conductivity was determined in accordance with GB / T 3048.2 "Test methods for electrical properties of wires and cables - Part 2: Test for resistivity of metallic materials". (3) Temperature rise at 300A current: The temperature rise at 300A current is characterized by thermocouple temperature measurement. The temperature rise at 300A current is determined in accordance with the relevant temperature rise test method in GB / T 3956 "Conductors of Cables". (4) Electromagnetic radiation: The electromagnetic radiation was measured by an electromagnetic radiation analyzer, and the electromagnetic radiation was measured in accordance with the relevant test methods in GB 8702 "Electromagnetic Environment Control Limits"; (5) Bending life (10 times wire diameter): Characterized by repeated bending test machine, the bending life (10 times wire diameter) is determined with reference to the relevant bending test method in GB / T 2951.14-2008 standard entitled "General test methods for insulation and sheath materials of cables and optical cables - Part 14: General test methods for low temperature test".

[0061] The test results are shown in Table 2.

[0062] Table 2 Performance characterization of the medium-conductor products of Examples 1 to 4 and Comparative Example 1

[0063] By comparing Examples 1 to 4 in Table 2 with Comparative Example 1, it can be seen that in this scheme, the core 1 is strengthened by forming a Mg2Si phase through Mg-Si and the grain structure is optimized by Cu-Ti; structurally, the anti-radiation spiral groove 2 (increasing the heat dissipation area and weakening electromagnetic radiation) improves the strength and conductivity of the core 1, specifically the tensile strength ≥180MPa and the conductivity ≥60%IACS; this allows the wire to achieve EMC ≤50dBμV / m without a shielding layer; and the temperature rise at 300A current ≤60K (ambient temperature 25℃). The insulation layer 3 uses modified cross-linked polyethylene + 2%-3% nano-calcium carbonate to improve high voltage resistance and temperature resistance. It meets the requirement of 800V high voltage insulation breakdown voltage ≥30kV / mm; and the insulation performance is stable from -40℃ to 125℃. The wear-resistant protective layer 4 uses PEEK material to improve wear resistance and temperature resistance. Meets Shore hardness requirements ≥ D85, resisting automotive vibration and friction; withstands oil contamination and high temperatures in fast charging scenarios, meeting long-term operating temperature requirements ≥ 250℃. Meets 5C fast charging rate requirements and standards, with an overall density ≤ 2.8g / cm³, reducing weight by 35%-40% compared to copper shielded harnesses of the same specifications; bending life ≥ 12,000 cycles (bending radius 10 times wire diameter).

[0064] This application solution addresses the following shortcomings of traditional wire harnesses in the industry: 1. Structural and weight defects: The shielding layer increases the diameter of the wiring harness by 25%-30% (traditional wiring harness diameter ≥20mm), occupying a compact space inside the vehicle; the copper conductor density is 8.9g / cm³, and after the shielding layer is added, the weight of the wiring harness is more than 60% higher than that of aluminum wire of the same specification, increasing the energy consumption of the whole vehicle; 2. Performance and cost drawbacks: Contact resistance (typically ≥10mΩ) is easily formed between the shielding layer and the conductor, resulting in an additional temperature rise of ≥15K at 300A current, reducing transmission efficiency; the price of copper is 3-4 times that of aluminum, and the shielding layer processing and assembly process increases manufacturing costs by 20%-30%; 3. Reliability defects: The aluminum foil of the shielding layer is prone to breakage due to bending, and the copper mesh is prone to oxidation, which leads to the degradation of EMC performance (the electromagnetic radiation increases by 10%-15dBμV / m after 1 year of use); in addition, the shielding layer and the insulation layer have poor adhesion and are prone to delamination at a low temperature of -40℃, which poses a risk of leakage. 4. Existing aluminum wire technology that removes the shielding layer only achieves lightweighting by adding a simple coating to pure aluminum, without solving the problem of aluminum's EMC performance (electromagnetic radiation ≥65dBμV / m), and cannot be adapted to fast charging scenarios.

[0065] This solution has the following advantages: Unshielded EMC Design: Breaking through the technical inertia of requiring shielding layers, the design replaces traditional metal shielding layers by combining "Mg-Si-Cu-Ti alloy composition (optimizing current distribution and weakening electromagnetic radiation) + spiral grooves (changing the electromagnetic field propagation path)" to achieve EMC performance standards, while reducing the wire harness diameter by 25%-30%. This provides the conditions for further increasing the wire diameter and reducing resistance temperature rise. Synergistic optimization of strength and conductivity of aluminum-based alloys: By forming a Mg2Si strengthening phase with Mg and Si (increasing tensile strength to ≥180MPa, 50% higher than pure aluminum), and refining grains with Cu and Ti (reducing resistance, conductivity ≥60%IACS), the inherent contradiction of aluminum's "low strength and poor conductivity" is resolved, meeting the requirements of fast charging high current and vibration resistance. Multi-level reliability synergy: Nano-calcium carbonate is added to the insulation layer 3 to improve high voltage resistance and temperature resistance (stable performance at -40℃ to 125℃), and the PEEK protective layer ensures wear resistance and oil resistance (volume change ≤5% after 24h immersion in lubricating oil). Together with the conductor core, it forms a closed loop of "transmission-insulation-protection", and the bending life is increased by more than 50% compared with existing aluminum wires. Lightweight and cost balance: Replacing traditional aluminum, copper, or copper-clad aluminum wires with aluminum alloy wires and removing the shielding layer reduces material costs by 20%-30% and wire harness weight by 30%-40%. At the same time, it reduces shielding layer processing steps and improves assembly efficiency by 37.5%, balancing technical performance and industrial economics.

[0066] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. An aluminum alloy wire, characterized in that, The wire core comprises, by weight percentage, the following components: Mg: 0.9% to 1.1%; Si: 0.45% to 0.55%; Cu: 0.1% to 0.2%; Ti: 0.03% to 0.04%; The balance is Al and unavoidable impurities, wherein the impurity content is ≤0.4%.

2. The aluminum alloy wire as described in claim 1, characterized in that, The surface of the wire core is provided with a radiation-reducing spiral groove.

3. The aluminum alloy wire as described in claim 2, characterized in that, The depth of the radiation-reducing spiral groove ranges from 0.3 mm to 0.5 mm; and / or, The pitch of the radiation-reducing spiral groove ranges from 5 mm to 7 mm.

4. The aluminum alloy wire as described in claim 1, characterized in that, The aluminum alloy wire also includes an insulation layer, which covers the outside of the wire core, and the insulation layer contains 2% to 3% by weight of modified cross-linked polyethylene with nano-calcium carbonate.

5. The aluminum alloy wire as described in claim 4, characterized in that, The aluminum alloy wire also includes a wear-resistant protective layer, which covers the outside of the insulation layer.

6. A process for preparing aluminum alloy wire, used to prepare the aluminum alloy wire as described in any one of claims 1 to 5, characterized in that, Includes the following steps: The raw material weighing step; wherein the raw material comprises the following components by weight percentage: Mg: 0.9% to 1.1%, Si: 0.45% to 0.55%, Cu: 0.1% to 0.2%, Ti: 0.03% to 0.04%, with the balance being Al and unavoidable impurities, wherein the impurity content is ≤0.4%; Raw material processing steps: After melting and heat preservation of the raw material, an aluminum alloy rod is made, and the aluminum alloy rod is drawn and annealed to obtain the wire core.

7. The preparation process of aluminum alloy wire as described in claim 6, characterized in that, Following the raw material processing step, the preparation process of the aluminum alloy wire further includes: Radiation-reducing spiral grooves are machined on the surface of the wire core using a forming mold.

8. The preparation process of aluminum alloy wire as described in claim 6, characterized in that, Following the raw material processing step, the preparation process of the aluminum alloy wire further includes: In the insulation coating step, modified cross-linked polyethylene with 2% to 3% nano-calcium carbonate added is heated to melt and then coated onto the outside of the wire core; segmented water cooling is used to cool it to room temperature.

9. The preparation process of aluminum alloy wire as described in claim 8, characterized in that, Following the insulation layer coating step, the manufacturing process of the aluminum alloy wire further includes: The wear-resistant protective layer coating step involves heating PEEK material to a molten state and then coating it over the insulation layer.

10. A car charging station, characterized in that, Includes aluminum alloy wire as described in any one of claims 1 to 5.

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