New energy vehicle megawatt super-fast charging copper-clad aluminum wire harness and production method

Abstract

The application discloses a new energy vehicle megawatt super-fast charging copper-clad aluminum wire harness and a production method. The product is formed by twisting multiple copper-clad aluminum monofilaments. Each monofilament is seamlessly welded with a copper strip outside an aluminum rod by argon arc welding to form a continuous metallurgical bonding layer, which avoids the contact resistance from rising due to the peeling of the copper layer, the peeling and the creep of the aluminum core, and meets the durability and connection reliability requirements of megawatt fast charging. In the production method, the monofilament is sequentially subjected to peeling and cleaning, argon arc welding, multi-stage continuous drawing and protective atmosphere annealing, so that the internal stress is eliminated, the flexibility and fatigue resistance of the wire are significantly improved, and the defects of large internal stress and easy brittle fracture in the existing process are solved.

Description

Technical Field

[0001] This invention relates to a copper-clad aluminum wire harness and its manufacturing method, and more particularly to a megawatt-level ultra-fast charging copper-clad aluminum wire harness for new energy vehicles and its manufacturing method. Background Technology

[0002] As charging power gradually enters the megawatt range, higher requirements are placed on the conductivity, heat resistance, shielding performance, and reliability of high-voltage charging harnesses. Meanwhile, vehicle lightweighting is a key way to improve driving range, and as a core component for high-current transmission, high-voltage harnesses must achieve weight and cost reduction while meeting electrical performance requirements.

[0003] Traditional pure copper high-voltage wiring harnesses are heavy and have high raw material costs; while pure aluminum wiring harnesses have significant advantages in weight reduction, they suffer from drawbacks such as easy joint breakage, poor contact stability, high temperature rise under high current conditions, and insufficient processing compatibility. Existing copper-clad aluminum conductors mostly use single-strand or simple stranded structures, with the copper layer and aluminum core mostly mechanically covered or overlapped, lacking continuous metallurgical bonding. Under high current transmission and thermal cycling conditions, the copper layer is prone to peeling, delamination, or even stripping, resulting in a reduced conductive cross-sectional area, localized overheating, and a surge in contact resistance due to aluminum core creep during end connections. These issues fail to meet the comprehensive requirements of megawatt-level ultra-fast charging for long-term durability and connection reliability.

[0004] Furthermore, existing production methods for copper-clad aluminum conductors mostly employ longitudinal lamination or drawing / extrusion, making it difficult to form a seamless metallurgical interface. The lack of targeted annealing and softening treatment after drawing, or the unreasonable annealing process, results in significant residual internal stress in the conductor, leading to poor flexibility, low elongation at break, and susceptibility to brittle fracture under vehicle wiring and vibration conditions. Moreover, the lack of systematic parameter matching between process steps makes it impossible to consistently obtain copper-clad aluminum monofilaments with uniform copper layer, high concentricity, and excellent overall performance. Therefore, there is an urgent need for a copper-clad aluminum wire harness and production method that can guarantee megawatt-level high-current transmission capacity, possess good flexibility and connection reliability, and whose production process is compatible with existing equipment. Summary of the Invention

[0005] To address the shortcomings of the aforementioned technologies, this invention provides a megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles and its manufacturing method.

[0006] To solve the above technical problems, the technical solution adopted by the present invention is: a megawatt-level ultra-fast charging copper-clad aluminum wire harness for new energy vehicles, including copper-clad aluminum conductors; Copper-clad aluminum wires are connected to the battery pack connector via battery pack terminals; The copper-clad aluminum wire is connected to the charging socket connector via the charging socket terminals; Copper-clad aluminum conductors consist of multiple strands of twisted copper-clad aluminum monofilaments, with each monofilament being uniformly wrapped around an aluminum rod by a copper strip to form a continuous metallurgically bonded wire bundle.

[0007] Furthermore, the charging dock connector is equipped with a slow charging connector, a grounding terminal, and a signal connector; Furthermore, it also includes fixed structures; The fixing structure includes: a rubber bushing that wraps around part of the copper-clad aluminum wire; A metal sheet metal bracket for connecting copper-clad aluminum wires; cable ties for securing the metal sheet metal bracket to the copper-clad aluminum wires, or for securing the metal sheet metal bracket to the copper-clad aluminum wires.

[0008] A method for producing copper-clad aluminum conductors for megawatt-level ultra-fast charging copper-clad aluminum wire harnesses in new energy vehicles includes the following steps: Step 1: High-purity aluminum rods are sequentially peeled, cleaned, and dried to remove the oxide layer and oil stains on the surface; Step 2: After leveling and degreasing, pure copper strips are tightly wrapped around the outside of the high-purity aluminum rods using a mold, and argon arc welding is used to seamlessly weld the copper strips, so that the copper layer and the aluminum core form a continuous metallurgical bond, resulting in a welded blank; Step 3: The welded blank is continuously drawn to the target outer diameter through multiple stages, and the copper layer thickness and concentricity are controlled by simultaneous cooling during the drawing process; Step 4: After drawing, the drawn blank is annealed and softened in a protective atmosphere furnace to eliminate internal stress, resulting in copper-clad aluminum monofilaments; Step 5: The copper-clad aluminum monofilaments are stranded into multiple strands according to the target cross-sectional area, and an insulation layer is extruded onto the outside of the stranded conductors to produce copper-clad aluminum wires.

[0009] Further, in step one, a peeling machine is used to remove the oxide layer on the surface of the high-purity aluminum rod, and the peeling thickness is controlled between 0.05 mm and 0.15 mm; the rod is then ultrasonically cleaned in alkaline cleaning solution and deionized water for 5 min to 10 min in sequence, and dried in hot air at 80℃ to 120℃.

[0010] Further, in step two, a pure copper strip with a thickness of 0.1mm to 0.3mm is selected, leveled, and then uniformly wrapped around the outer surface of the aluminum rod with a 30° to 60° wrapping angle using a guide mold; the copper strip joint is seamlessly welded using an argon arc welding machine under the conditions of welding current of 80A to 150A and welding speed of 0.5m / min to 1.5m / min, with a weld width ≤ 0.5mm, and a metallurgical bonding layer with a thickness of 5μm to 20μm is formed at the interface between the copper layer and the aluminum rod.

[0011] Further, in step three, the welding blank is continuously drawn in 5 to 10 passes, with a diameter reduction rate of 15% to 25% per pass, and the drawing speed is controlled at 20m / min to 60m / min; emulsion or mineral oil-based lubricating coolant is used for cooling and lubrication, and the copper layer thickness after drawing accounts for 15% to 25% of the total diameter of the single wire, with a concentricity ≥90%.

[0012] Furthermore, in the annealing and softening step four, the copper-clad aluminum monofilament is annealed to meet the following requirements: elongation at break ≥200%, tensile strength ≥5MPa, and conductor DC resistance ≤0.230Ω / km at 20℃.

[0013] Furthermore, multiple copper-clad aluminum monofilaments are concentrically stranded according to the target cross-sectional area, with a stranding pitch ratio of 8 to 16. After stranding, a cross-linked polyethylene or silicone rubber insulation layer is extruded on the outside of the conductor, with an insulation thickness of 0.8 mm to 2.0 mm, to produce a copper-clad aluminum conductor.

[0014] Furthermore, when connecting the ends of the copper-clad aluminum wires to the battery pack terminals or charging socket terminals, the welding parameters for ultrasonic welding are controlled as follows: time 3800ms~4200ms, welding energy consumption 2800J~3200J, amplitude set to 90%~95%, pressure set to 0.3MPa~0.35MPa, post-weld height 6.7mm~6.9mm, and welding tensile force ≥4000N.

[0015] This invention discloses a megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles and its production method. This patent solves the problems existing in the background technology by optimizing the product structure and production method. In terms of product structure, a conductor composed of multiple strands of copper-clad aluminum monofilaments is used. Each monofilament is seamlessly welded to the outside of the aluminum rod using argon arc welding, forming a continuous, non-delaminating metallurgical bonding layer. This completely avoids the copper layer peeling and delamination problems that easily occur under high-current thermal cycling in traditional mechanical coating. Simultaneously, the aluminum core is uniformly coated with copper, effectively suppressing the surge in contact resistance caused by aluminum core creep, meeting the long-term durability and connection reliability requirements of megawatt-level ultra-fast charging. In terms of production method, seamless welding of the copper strip through argon arc welding ensures the metallurgical bonding of the interface. Further, multi-stage continuous drawing and annealing softening treatment with specific parameters eliminate internal stress, significantly improving flexibility and fatigue resistance, and solving the defects of high internal stress and easy brittle fracture caused by existing processes. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention.

[0017] In the diagram, 1 is the battery pack terminal; 2 is the copper-clad aluminum wire; 3 is the battery pack connector; 4 is the charging dock connector; 5 is the charging dock terminal; 6 is the cable tie; 7 is the metal sheet metal bracket; 8 is the slow charging connector; 9 is the grounding terminal; 10 is the signal connector; and 11 is the rubber bushing. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0019] Example 1; like Figure 1The product shown is a megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles. In this embodiment, the wiring harness assembly is used to connect the vehicle battery pack and the DC fast charging base. The wiring harness assembly includes two copper-clad aluminum wires 2, which are bundled together at intervals by cable ties 6. Each wire is made of multiple strands of copper-clad aluminum monofilaments twisted together, and a cross-linked polyethylene insulation layer is provided on the outside of the conductor. The ends of the conductors are stripped to remove a section of the insulation layer, exposing the bare conductor. The exposed conductor ends are connected to the battery pack terminal 1 and the charging base terminal 5 respectively by ultrasonic welding.

[0020] The battery pack terminals are installed within the sheath of battery pack connector 3, which contains sealing rings and waterproof rubber rings, and is secured by a secondary locking mechanism. The charging socket terminals are also ultrasonically welded to the other end of the conductor and installed within the sheath of charging socket connector 4. The housing of the charging socket connector also integrates a slow-charging connector 8, a grounding terminal 9, and a signal connector 10, used for auxiliary connection and grounding protection during slow charging. The slow-charging connector provides the rated current during slow charging; the grounding terminal is grounded to the vehicle body; and the signal connector is used to transmit charging handshake signals and temperature monitoring signals.

[0021] The wiring harness assembly 1 is bundled with a metal sheet metal bracket 7 by cable ties 6. The sheet metal bracket is made of galvanized steel sheet of a certain thickness and has mounting holes at the bottom, which can be fixed to the longitudinal beam of the vehicle body by M6 bolts.

[0022] The copper-clad aluminum conductor passes through the rubber bushing 11, which tightly wraps around the outer surface of the conductor. This prevents any relative displacement of the conductor in the axial and circumferential directions.

[0023] Example 2; High-purity aluminum rods with a purity of 99.7% and a diameter of 12mm were selected. A CNC peeling machine was used to remove the oxide layer from the aluminum rod surface, with a peeling thickness set at 0.05mm. After peeling, the diameter of the aluminum rod decreased to 11.9mm. The peeled aluminum rods immediately entered the cleaning section, where they were ultrasonically cleaned for 5 minutes each in a weakly alkaline cleaning solution with a pH of 9.5 at 60℃, followed by ultrasonic rinsing in deionized water for 5 minutes. The cleaned aluminum rods were then dried in a 120℃ hot air dryer at a wind speed of 10m / s. After drying, the residual water content on the aluminum rod surface was less than 0.01mg / cm², and the surface was free of oil stains and oxide discoloration.

[0024] Pure copper strips with a thickness of 0.1 mm and a width of 38 mm are selected. The copper strips are first leveled by leveling rollers, then soaked in a degreasing tank of sodium carbonate solution at 50°C for 2 minutes, followed by rinsing with clean water and drying with hot air. The treated aluminum rod and copper strip are fed together into the coating mold with a guide angle of 30°. The copper strip is evenly wrapped around the outer surface of the aluminum rod at a 30° coating angle, and the two sides of the copper strip are joined to form a longitudinal seam.

[0025] The longitudinal seam was welded using an argon arc welding machine with a welding current set to 80A, a welding voltage of 12V, a welding speed of 0.5m / min, and an argon gas flow rate of 8L / min. After welding, the weld was continuous, free of porosity and cracks, and the measured weld width was 0.4mm, less than the requirement of 0.5mm. The copper layer and aluminum rod formed a metallurgical bond under the welding heat. Five random points at the interface were used to measure the bond layer thickness using a scanning electron microscope. The average thickness was 5.2μm, the minimum was 4.8μm, and the maximum was 5.5μm, falling entirely within the 5-20μm range. A weld blank with an outer diameter of approximately 12.3mm was obtained.

[0026] The welding blank was subjected to multi-stage continuous drawing. An 8-die continuous drawing machine was used, with 5 passes actually executed. The diameter reduction rate for each pass was 15% for the first pass, 16% for the second, 18% for the third, 17% for the fourth, and 15% for the fifth. The drawing speed was controlled at the lower limit of 20 m / min. During the drawing process, an emulsion (5% emulsion oil + 95% water) was used for cooling and lubrication, with the emulsion temperature controlled at 25-30℃ and a flow rate of 20 L / min. After drawing, the outer diameter of the single wire was 1.8 mm, and the copper layer thickness, measured by cross-sectional metallography, was 0.27 mm, accounting for 15.0% of the total single wire diameter. The concentricity, tested by eddy current method, was 92%, meeting the requirement of ≥90%.

[0027] The drawn monofilaments were placed in a protective atmosphere annealing furnace, which was purged with high-purity nitrogen and had an oxygen content of less than 50 ppm. The annealing temperature was set to 200℃, and the holding time was 3 hours. After annealing, the monofilaments were cooled in the furnace to below 60℃ and then removed. Mechanical and electrical tests were performed on the annealed monofilament samples: the elongation at break was tested according to GB / T228.1-2021, and the result was 210%; the tensile strength was 5.3 MPa; the DC resistance of the conductor at 20℃ was measured using the double-arm bridge method, and the resistance of a 1m long monofilament was 0.228Ω.

[0028] In this embodiment, the target cross-sectional area is set at 50 mm², and the diameter of a single wire is 1.8 mm. Therefore, the required number of strands is 50 / (π×0.9²)≈19.6, and 19 strands are chosen. The stranding method uses a 1+6+12 three-layer concentric stranding with a stranding pitch ratio of 8. After stranding, the outer diameter of the conductor is approximately 8.1 mm. Then, a cross-linked polyethylene insulation layer is extruded from the conductor using an extruder, with an insulation thickness of the lower limit of 0.8 mm. The final outer diameter of the conductor is approximately 9.7 mm. Testing shows that the insulation layer eccentricity is less than 10%, the insulation resistance is greater than 10000 MΩ·km, and the withstand voltage test is passed. This completes the preparation of the copper-clad aluminum conductor. After subsequent cutting, stripping, ultrasonic welding, and connector assembly, the conductor can be made into a complete wire harness assembly.

[0029] Example 2; The high-purity aluminum rod has a diameter of 12mm, and the peeling thickness is taken as the median value of 0.10mm, resulting in a diameter of 11.8mm after peeling. Cleaning conditions: alkaline cleaning solution temperature 70℃, ultrasonic cleaning for 8 minutes, deionized water rinsing for 8 minutes, and drying temperature of 100℃.

[0030] The pure copper strip thickness is 0.20mm, and the width is approximately 40mm based on the aluminum rod diameter. The wrap angle is 45°, and the mold guide angle is 45°. Argon arc welding parameters: welding current 115A, welding speed 1.0m / min, argon flow rate 10L / min. The measured weld width is 0.3mm, and the average metallurgical bonding layer thickness is 12.5μm. The outer diameter of the weld blank is approximately 12.5mm.

[0031] Eight consecutive drawing passes were used, with diameter reduction rates of 18%, 20%, 22%, 20%, 22%, 20%, 18%, and 15% for each pass, resulting in an average diameter reduction of approximately 19.4%. The drawing speed was 40 m / min. Mineral oil-based lubricant with a viscosity of 40 cSt and a flow rate of 15 L / min was used for lubrication and cooling. After drawing, the outer diameter of the single filament was 2.0 mm, the copper layer thickness was 0.40 mm, accounting for 20.0% of the total single filament diameter, and the concentricity was 95%.

[0032] Annealing was carried out in a nitrogen-hydrogen mixture of 95% N2 and 5% H2 at a temperature of 280℃ for 2 hours. After annealing, the elongation at break of the monofilament was 245%, the tensile strength was 6.2 MPa, and the DC resistance at 20℃ was 0.215 Ω / km.

[0033] In this embodiment, 37 monofilaments are used, with the diameter of each monofilament controlled to 1.55 mm after drawing. Alternatively, this embodiment can be simplified as follows: based on a target cross-sectional area of ​​70 mm², a monofilament diameter of 1.6 mm and 35 strands are selected, twisted in a 1+6+12+16 configuration with a twist ratio of 12. After twisting, the conductor's outer diameter is approximately 9.6 mm. A silicone rubber insulation layer is extruded, with an insulation thickness of 1.4 mm, resulting in a final conductor outer diameter of approximately 12.4 mm. The copper-clad aluminum conductor prepared in this embodiment exhibits excellent comprehensive performance and is suitable as a conductor material for megawatt-level charging harnesses.

[0034] Example 3; The high-purity aluminum rod has a diameter of 15mm, with a peeling thickness of up to the upper limit of 0.15mm, resulting in a diameter of 14.7mm after peeling. Cleaning conditions: alkaline cleaning solution temperature 80℃, ultrasonic cleaning for 10min, deionized water rinsing for 10min, and drying temperature 120℃. The pure copper strip has a thickness of 0.30mm and a width of approximately 48mm. The wrap angle is 60°, and the mold guide angle is 60°. Argon arc welding parameters: welding current 150A, welding speed 1.5m / min, argon flow rate 12L / min. The measured weld width is 0.45mm, the average metallurgical bonding layer thickness is 18.5μm, and the maximum is 19.8μm. The outer diameter of the weld blank is approximately 15.6mm.

[0035] Ten consecutive drawing passes were used, with the diameter reduction rate controlled at approximately 25% per pass (e.g., 25%, 24%, 25%, 23%, 25%, 24%, 25%, 23%, 24%, 22%). The drawing speed was capped at 60 m / min. Fully synthetic drawing oil with a viscosity of 60 cSt and a flow rate of 25 L / min was used for lubrication and cooling, and a circulating cooling system was installed to ensure the oil temperature did not exceed 45°C. After drawing, the outer diameter of the single wire was 1.6 mm, the copper layer thickness was 0.40 mm, accounting for 25.0% of the total single wire diameter, and the concentricity was 91%.

[0036] Annealing was performed under a pure argon protective atmosphere at a temperature of 350℃ for 1 hour. After annealing, the elongation at break of the single filament was 202%, the tensile strength was 5.1 MPa, and the DC resistance at 20℃ was 0.229 Ω / km.

[0037] The target cross-sectional area is 95 mm², and a single wire diameter of 1.6 mm is selected. The required number of strands is 95 / (π×0.8²) = 47.2, so 49 strands are selected and twisted in a 1+6+12+18+12 configuration. The twisting pitch ratio is set to the upper limit of 16. After twisting, the outer diameter of the conductor is approximately 12.8 mm. A cross-linked polyethylene insulation layer is extruded, with an insulation thickness of 2.0 mm, resulting in a final conductor outer diameter of approximately 16.8 mm. This conductor has a large current-carrying capacity and is suitable for higher-power megawatt-level charging scenarios.

[0038] The above embodiments are not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present invention are also within the protection scope of the present invention.

Claims

1. A megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles, characterized in that: Including copper-clad aluminum conductors (2); The copper-clad aluminum wire (2) is connected to the battery pack connector (3) through the battery pack terminal (1). The copper-clad aluminum wire (2) is connected to the charging socket connector (4) through the charging socket terminal (5). The copper-clad aluminum conductor (2) includes multiple strands of copper-clad aluminum monofilaments, and each copper-clad aluminum monofilament is uniformly wrapped with an aluminum rod by a copper strip to form a continuous metallurgically bonded wire bundle.

2. The megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles according to claim 1, characterized in that: The charging dock connector (4) is connected to a slow charging connector (8), a grounding terminal (9), and a signal connector (10).

3. The megawatt-level ultra-fast charging copper-clad aluminum wiring harness for new energy vehicles according to claim 1, characterized in that: It also includes fixed structures; The fixing structure includes: a rubber bushing (11) that wraps around part of the copper-clad aluminum wire (2). Metal sheet metal bracket (7) is connected to copper-clad aluminum wire (2); cable tie (6) is used to bind the metal sheet metal bracket (7) to the copper-clad aluminum wire (2) or to the copper-clad aluminum wire (2).

4. A method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles as described in any one of claims 1-3, characterized in that, Includes the following steps: Step 1: The high-purity aluminum rod is peeled, cleaned, and dried sequentially to remove the oxide layer and oil stains from the surface. Step 2: After leveling and degreasing, the pure copper strip is tightly wrapped around the outside of the high-purity aluminum rod using a mold. Argon arc welding is then used to seamlessly weld the copper strip, forming a continuous metallurgical bond between the copper layer and the aluminum core, resulting in a welded blank. Step 3: The welded blank is continuously drawn to the target outer diameter through multiple stages. During the drawing process, simultaneous cooling is used to control the copper layer thickness and concentricity. Step 4: After drawing, the blank is annealed and softened in a protective atmosphere furnace to eliminate internal stress, resulting in copper-clad aluminum monofilaments. Step 5: The copper-clad aluminum monofilaments are stranded into multiple strands according to the target cross-sectional area, and an insulation layer is extruded onto the outside of the stranded conductors to produce copper-clad aluminum wires.

5. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 4, characterized in that: In step one, a peeling machine is used to remove the oxide layer on the surface of the high-purity aluminum rod, and the peeling thickness is controlled between 0.05 mm and 0.15 mm. The rod is then ultrasonically cleaned in alkaline cleaning solution and deionized water for 5 min to 10 min in sequence, and dried in hot air at 80℃ to 120℃.

6. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 4, characterized in that: In step two, a pure copper strip with a thickness of 0.1mm to 0.3mm is selected, leveled, and then uniformly wrapped around the outer surface of the aluminum rod at a 30° to 60° wrapping angle using a guide mold. The copper strip joint is then seamlessly welded using an argon arc welding machine at a welding current of 80A to 150A and a welding speed of 0.5m / min to 1.5m / min. The weld width is ≤0.5mm, and a metallurgical bonding layer with a thickness of 5μm to 20μm is formed at the interface between the copper layer and the aluminum rod.

7. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 4, characterized in that: In step three, the welding blank is continuously drawn in 5 to 10 passes, with a diameter reduction rate of 15% to 25% per pass, and the drawing speed is controlled at 20m / min to 60m / min. Emulsion or mineral oil-based lubricating coolant is used for cooling and lubrication. After drawing, the copper layer thickness accounts for 15% to 25% of the total diameter of the single wire, and the concentricity is ≥90%.

8. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 4, characterized in that: In the annealing and softening step of step four, the copper-clad aluminum monofilament is annealed to meet the following requirements: elongation at break ≥200%, tensile strength ≥5MPa, and conductor DC resistance ≤0.230Ω / km at 20℃.

9. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 8, characterized in that: The process involves concentrically stranding multiple copper-clad aluminum monofilaments according to the target cross-sectional area, with a stranding pitch ratio of 8 to 16. After stranding, a cross-linked polyethylene or silicone rubber insulation layer is extruded onto the conductor, with an insulation thickness of 0.8 mm to 2.0 mm, to produce a copper-clad aluminum conductor.

10. The method for producing copper-clad aluminum conductors for preparing megawatt-level ultra-fast charging copper-clad aluminum wire harnesses for new energy vehicles according to claim 9, characterized in that: When the copper-clad aluminum wire ends are connected to the battery pack terminal or charging socket terminal, the ultrasonic welding parameters are controlled as follows: time 3800ms~4200ms, welding energy consumption 2800J~3200J, amplitude set to 90%~95%, pressure set to 0.3MPa~0.35MPa, post-weld height 6.7mm~6.9mm, and welding tensile force ≥4000N.

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