A flame-retardant cable for new energy vehicles

Abstract

The application discloses a flame-retardant cable for a new energy automobile and relates to the technical field of electric wires and cables, which comprises a conductor layer, a first flame-retardant layer, a filling layer, an insulating layer, a second flame-retardant layer, a reinforcing tape layer and an outer protective sleeve as the outermost layer. The conductor layer is composed of multiple groups of wires, each group of wires is individually coated with the first flame-retardant layer, the multiple groups of coated wires are aggregated to form a cable core, the cable core is externally sleeved with the insulating layer, the insulating layer comprises an insulating inner layer for collecting the cable core and an insulating outer layer wrapped outside, the gap between the cable core and the insulating inner layer is provided with the filling layer, the second flame-retardant layer is sleeved with the insulating layer, the second flame-retardant layer adopts a composite structure and comprises an extrusion-formed coating layer and a spiral-wound winding layer from inside to outside, and the outer protective sleeve is sleeved with the second flame-retardant layer.

Description

Technical Field

[0001] This application relates to the field of wire and cable technology, specifically to a flame-retardant cable for new energy vehicles. Background Technology

[0002] Compared to traditional vehicles, charging time and safety remain key constraints for current new energy vehicles. In common usage scenarios such as parking lots and highway service areas, charging cables need to withstand sun exposure, weathering, or oil corrosion. Moreover, charging cables also have to endure frequent dragging, pulling, and friction. Due to the limitations of the objective usage environment, charging cables must have good flexibility, wear resistance, and corrosion resistance. In addition, considering the safety and fire resistance during charging, charging cables need to have heat resistance, flame retardancy, and good insulation properties. To meet these requirements, current solutions are to comprehensively address multiple needs such as flame retardancy and mechanical properties by filling the cable with magnesium hydroxide flame retardant or using flame retardant materials such as ceramicized silicone rubber to coat the cable.

[0003] However, the overall approach to meeting the flame retardant and fireproof requirements of cables is to achieve comprehensive flame retardancy by stacking multiple layers of materials in the radial direction of the cable. In contrast, the flame retardant structure of the cable in the axial direction is simple, and the flame retardant effect is relatively poor. In addition, simply stacking flame retardant materials makes the cable itself more bulky and inhibits the mechanical properties of the cable.

[0004] Therefore, it is necessary to provide a flame-retardant cable for new energy vehicles to solve the problems mentioned in the background art. Summary of the Invention

[0005] To achieve the above objectives, this application provides the following technical solution: a flame-retardant cable for new energy vehicles, comprising: a conductor layer, a first flame-retardant layer, a filler layer, an insulation layer, a second flame-retardant layer, a reinforcing wrapping layer, and an outermost protective sheath. The conductor layer consists of multiple sets of conductors, each set of conductors being individually covered with the first flame-retardant layer. The multiple sets of covered conductors are aggregated to form a cable core, which is covered with an insulation layer. The insulation layer includes an inner insulation layer that bundles the cable core and an outer insulation layer that wraps around it. A filler layer is placed in the gap between the cable core and the inner insulation layer. The second flame-retardant layer is covered with the insulation layer. The second flame-retardant layer adopts a composite structure, including an extruded covering layer and a spirally wound winding layer from the inside out. The outer protective sheath is covered with the second flame-retardant layer.

[0006] Furthermore, as a preferred embodiment, limiting protrusions are evenly distributed on the outer wall surface of the insulating outer layer, and a retaining groove is provided between adjacent limiting protrusions.

[0007] Furthermore, as a preferred embodiment, the covering layer includes a thin covering wall in contact with the insulating outer layer, and the thin covering wall has a covering flange with spiral protrusions.

[0008] Furthermore, as a preferred embodiment, the winding layer consists of multiple winding cables.

[0009] Furthermore, preferably, the winding path of the winding layer is confined within the gap between the spiral covering flanges.

[0010] Furthermore, as a preferred embodiment, the wrapping layer is squeezed to compress the covering thin wall below, so that it is tightly embedded in the retaining groove of the insulating outer layer. The wrapping layer, the covering thin wall, and the limiting protrusion of the insulating outer layer form a strong structure that is nested and mutually limiting in both the radial and axial directions.

[0011] Furthermore, as a preferred embodiment, a reinforcing wrapping layer is provided between the second flame-retardant layer and the outer protective sleeve.

[0012] Compared with the prior art, this application provides a flame-retardant cable for new energy vehicles, which has the following advantages: In this application, the sheathing layer uses ordinary ceramicized silicone rubber with superior mechanical properties to ensure structural strength, while the winding layer uses ceramicized silicone rubber with high zinc borate content, sacrificing some mechanical properties in exchange for excellent flame retardancy. At the same time, the spiral structure changes the stress mode, effectively compensating for the shortcomings of the high flame retardant material itself, making the second flame retardant layer flexible at room temperature and quickly forming a high-strength ceramic protective layer at high temperature. The ceramicized silicone rubber of this formulation was not burned through after being impacted by a flame at ℃ for minutes, and the surface was free of cracks, forming a self-supporting dense ceramic layer. Meanwhile, the winding layer compresses the sheathing thin wall below, making it tightly embedded in the retention groove of the insulating outer layer. The limiting protrusions of the winding layer, the sheathing thin wall, and the insulating outer layer form a strong structure of mutual nesting and mutual limiting in both radial and axial directions, effectively constructing a composite flame retardant structure in both the axial and radial directions of the cable, while ensuring that the cable structure is compact and has better bending performance. Attached Figure Description

[0013] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic diagram of the overall structure of a flame-retardant cable used in new energy vehicles. Figure 2 This is a schematic diagram of the insulation layer structure of a flame-retardant cable used in new energy vehicles. Figure 3 This is a schematic diagram of the second flame-retardant layer structure of a flame-retardant cable for new energy vehicles. Figure 4 This is a cross-sectional schematic diagram of the sheathing and winding layers of a flame-retardant cable used in new energy vehicles. Figure 5 This is a schematic diagram of the bonding of the insulation layer and the second flame-retardant layer in a flame-retardant cable used in new energy vehicles. In the diagram: 1. Conductor layer; 2. First flame-retardant layer; 3. Filler layer; 4. Insulation layer; 41. Inner insulation layer; 42. Outer insulation layer; 43. Limiting protrusion; 44. Retention groove; 5. Second flame-retardant layer; 51. Covering layer; 511. Covering flange; 512. Covering thin wall; 52. Wrapping layer; 521. Wrapped cable; 6. Outer protective sheath; 7. Reinforcing wrapping layer. Detailed Implementation

[0014] Please see Figures 1-5 In this embodiment of the application, a flame-retardant cable for new energy vehicles includes: a conductor layer 1, a first flame-retardant layer 2, a filler layer 3, an insulation layer 4, a second flame-retardant layer 5, a reinforcing wrapping layer 7, and an outermost protective sleeve 6. The conductor layer 1 is composed of multiple sets of conductors, each set of conductors is individually covered with the first flame-retardant layer 2, and the multiple sets of covered conductors are aggregated to form a cable core, which is covered with an insulation layer 4. The insulation layer 4 includes an inner insulation layer 41 that bundles the cable core and an outer insulation layer 42 that wraps around it. A filler layer 3 is placed in the gap between the cable core and the inner insulation layer 41. The second flame-retardant layer 5 is covered with the insulation layer 4. The second flame-retardant layer 5 adopts a composite structure, which includes an extruded covering layer 51 and a spirally wound winding layer 52 from the inside to the outside. The outer protective sleeve 6 is covered with the second flame-retardant layer 5.

[0015] It should be explained that the first flame-retardant layer 2 is preferably ceramicized silicone rubber, which can be ceramicized at high temperature to form a protective shell. The insulating layer 4 is preferably Mxene-reinforced halogen-free flame-retardant and thermally conductive polyolefin material. The filler layer 3 is a mixture of magnesium hydroxide flame retardant and ceramic fiber in a volume ratio of 3:1, which has good heat insulation and flame-retardant effects.

[0016] In a preferred embodiment, limiting protrusions 43 are evenly distributed on the outer wall surface of the insulating outer layer 42, and a retaining groove 44 is provided between adjacent limiting protrusions 43.

[0017] In a preferred embodiment, the covering layer 51 includes a covering thin wall 512 in contact with the insulating outer layer 42, and the covering thin wall 512 has a covering flange 511 that is spirally raised.

[0018] In a preferred embodiment, the winding layer 52 is composed of multiple winding cables 521, which are ceramicized silicone rubber containing 12% zinc borate.

[0019] In a preferred embodiment, the winding path of the winding layer 52 is confined within the gap between the spiral covering flanges 511.

[0020] In a preferred embodiment, the winding layer 52 presses the underlying covering thin wall 512 so that it is tightly embedded in the retaining groove 44 of the insulating outer layer 42. The winding layer 52, the covering thin wall 512 and the limiting protrusion 43 of the insulating outer layer 42 form a strong structure that is nested and mutually limiting in both the radial and axial directions.

[0021] It should be explained that the coating layer 51 uses ordinary ceramicized silicone rubber with better mechanical properties to ensure structural strength, while the winding layer 52 uses ceramicized silicone rubber with high zinc borate content, sacrificing some mechanical properties in exchange for excellent flame retardancy. At the same time, the spiral structure changes the stress mode, effectively compensating for the lack of mechanical properties of the high flame retardant material itself. This makes the second flame retardant layer 5 flexible at room temperature and quickly forms a high-strength ceramic protective layer at high temperature. The ceramicized silicone rubber of this formulation was not burned through after being impacted by a flame at 1000℃ for 5 minutes, and there were no cracks on the surface, forming a self-supporting dense ceramic layer.

[0022] In a preferred embodiment, a reinforcing wrapping layer 7 is provided between the second flame-retardant layer 5 and the outer protective sleeve 6.

[0023] It should be explained that the reinforcing tape layer 7 is woven from quartz or high-silica glass fiber yarn, further enhancing the overall mechanical strength of the cable. The outermost layer is extruded with an outer protective sheath 6, which is made of modified SEBS thermoplastic elastomer, providing excellent environmental resistance and an initial fire barrier.

[0024] Through the aforementioned sophisticated multi-layered structural design and material synergy, the cable in this embodiment exhibits superior performance: its flame retardant performance passes the IEC60332-3-24 Class A bundled burning test, maintaining circuit integrity even after burning at 950℃ for 90 minutes; it has excellent fire resistance, with an insulation resistance greater than 100MΩ·km after burning at 750℃ / 90min; all materials are halogen-free, exhibiting excellent environmental performance during combustion, with a toxicity index CIT≤1.5 and a maximum smoke density Ds≤150; it also possesses high flexibility, with a minimum bending radius of only 4 times the cable's outer diameter (e.g., 24mm), making it suitable for wiring in confined spaces, with a long-term operating temperature up to 150℃ and a design life exceeding 40 years.

[0025] In specific implementation, the covering layer 51 uses ordinary ceramicized silicone rubber with better mechanical properties to ensure structural strength, while the winding layer 52 uses ceramicized silicone rubber with high zinc borate content, sacrificing some mechanical properties in exchange for excellent flame retardancy. At the same time, the spiral structure changes the stress mode, effectively compensating for the lack of mechanical properties of the high flame retardant material itself. This makes the second flame retardant layer 5 flexible at room temperature and quickly forms a high-strength ceramic protective layer at high temperature. The ceramicized silicone rubber of this formula was not burned through after being impacted by a flame at 1000°C for 5 minutes, and the surface was free of cracks, forming a self-supporting dense ceramic layer. Meanwhile, the winding layer 52 compresses the covering thin wall 512 below, making it tightly embedded in the retention groove 44 of the insulating outer layer 42. The winding layer 52, the covering thin wall 512 and the limiting protrusions 43 of the insulating outer layer 42 form a strong structure of mutual nesting and mutual limiting in both radial and axial directions. This effectively constructs a composite flame retardant structure in both the axial and radial directions of the cable, while ensuring that the cable structure is compact and has better bending performance.

[0026] The above description is merely a preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this application, based on the technical solution and application concept of this application, should be included within the scope of protection of this application.

Claims

1. A flame-retardant cable for new energy vehicles, characterized in that: The cable core consists of a conductor layer (1), a first flame-retardant layer (2), a filler layer (3), an insulation layer (4), a second flame-retardant layer (5), a reinforcing wrapping layer (7), and an outermost protective sleeve (6). The conductor layer (1) is composed of multiple sets of conductors, each set of conductors is individually covered with a first flame-retardant layer (2). The multiple sets of covered conductors are aggregated to form a cable core, which is covered with an insulation layer (4). The insulation layer (4) includes an inner insulation layer (41) that bundles the cable core and an outer insulation layer (42) that wraps around it. A filler layer (3) is placed in the gap between the cable core and the inner insulation layer (41). The second flame-retardant layer (5) is covered with the insulation layer (4). The second flame-retardant layer (5) adopts a composite structure, which includes an extruded covering layer (51) and a spirally wound winding layer (52) from the inside to the outside. The outer protective sleeve (6) is covered with the second flame-retardant layer (5).

2. The flame-retardant cable for new energy vehicles according to claim 1, characterized in that: Limiting protrusions (43) are evenly distributed on the outer wall surface of the insulating outer layer (42), and a retaining groove (44) is provided between adjacent limiting protrusions (43).

3. The flame-retardant cable for new energy vehicles according to claim 1, characterized in that: The covering layer (51) includes a covering thin wall (512) in contact with the insulating outer layer (42), and the covering thin wall (512) has a covering flange (511) with spiral protrusions.

4. A flame-retardant cable for new energy vehicles according to claim 3, characterized in that: The winding layer (52) is composed of multiple winding cables (521).

5. A flame-retardant cable for new energy vehicles according to claim 4, characterized in that: The winding path of the winding layer (52) is restricted in the gap between the spiral covering flanges (511).

6. A flame-retardant cable for new energy vehicles according to claim 5, characterized in that: The winding layer (52) presses the underlying covering thin wall (512) so that it is tightly embedded in the stabilizing groove (44) of the insulating outer layer (42). The winding layer (52), the covering thin wall (512) and the limiting protrusion (43) of the insulating outer layer (42) form a strong structure that is nested and mutually limiting in both the radial and axial directions.

7. A flame-retardant cable for new energy vehicles according to claim 1, characterized in that: A reinforcing wrapping layer (7) is provided between the second flame-retardant layer (5) and the outer protective sleeve (6).

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