Ultrathin-wall high-strength superfine composite cable for new energy automobile

Abstract

The utility model discloses an ultra-thin-wall high-strength ultra-thin composite cable for a new energy automobile, which relates to the technical field of cables and comprises a first conductor part made of copper-clad steel materials. A plurality of groups of second conductor parts are twisted through a bunching machine and wrap the first conductor part in a surrounding manner to form a circular conductor structure; the insulating layer is coated outside the conductor part II; the central structure of the conductor adopts copper alloy, so that the overall tensile strength of the cable is improved, and the bending performance of the cable is improved; in the conductor bunching process, production can be performed by adopting an existing bunching machine, and equipment investment is not needed; wire harness processing can be carried out by adopting existing equipment, and equipment investment is not needed; the cross section of the electric wire can be reduced to 0.13-0.22 mm < 2 > from the traditional 0.35 mm < 2 >, so that the light weight of the wire harness is facilitated; the overall material consumption of the wire is reduced, the wire cost is saved and the benefit is obvious; the outer diameter of the wire is reduced, the space occupied by the wire harness is reduced, and the occupied space in the vehicle is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of cables, and in particular to an ultra-thin-wall high-strength and ultra-fine composite cable for new energy vehicles. Background Art

[0002] In recent years, as the national environmental protection policy has been gradually improved, the electric vehicle industry has developed rapidly. For automobiles, wiring harnesses are like nerves, and their importance is self-evident. First, under the trend of electrification and intelligence, the demand for wiring harnesses for new energy vehicles is increasing, and the cost is increasing, which is doubled compared to the cost of traditional fuel vehicles. Secondly, the weight of wiring harnesses for new energy vehicles has increased, and the low-voltage wiring harness has reached about 25 kg, and the high-voltage wiring harness has reached 20 kg. The low-voltage wiring harness is 0.35mm thick. 2 The demand for copper is the largest; more importantly, copper, an important material for wire harnesses, is in short supply. It is estimated that the global copper supply gap will reach 500,000 tons in 2024. According to statistics, China's annual copper demand is about 15 million tons, accounting for more than 50% of the global consumption, and it is heavily dependent on imports; and the automotive industry, as a major user of copper, accounts for 13% of the country's demand, of which the use of wire harnesses accounts for half of the entire automotive industry. This year, copper prices have hit a record high of 76,000 yuan / ton. From this point of view, "reducing costs and weight, and reducing the use of copper materials" has become an urgent problem to be solved in the wire harness industry.

[0003] A Chinese invention patent (publication number CN104364852A) discloses a method for producing insulated wires, which records the use of copper alloy automotive wires, which have the disadvantages of high copper wire strength, inability to use a wire bundler to produce conductors, low production efficiency, and high production costs;

[0004] A Chinese invention patent (publication number CN103725929B) discloses an AL-Fe-Cu-Mg-Sb aluminum alloy for automotive wires and its wiring harness, which records that the use of aluminum alloy automotive wires has the disadvantages of low aluminum wire strength, poor bending performance, and easy breakage of crimped terminals.

[0005] The 0.22mm 2 The wires are soft in quality and have poor bending properties, so they are prone to breakage during vehicle assembly.

[0006] Therefore, in view of the above problems existing in the wiring harness used in new energy vehicles, a new wiring harness with optimized structure, light weight and high strength is designed to replace the 0.22mm wiring harness of traditional new energy vehicles. 2 , 0.35mm 2 The ultra-thin wall high-strength and ultra-fine composite cable of the wire is used to solve the above problems. Summary of the invention

[0007] The utility model aims to provide an ultra-thin-wall high-strength and ultra-fine composite cable for new energy vehicles with optimized structure, light weight and high strength.

[0008] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0009] An ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles, comprising:

[0010] A conductor part, wherein the conductor part is made of copper-clad steel;

[0011] Conductor two parts, multiple groups of the conductor two parts are twisted by a wire bundling machine and wrapped around the outside of the conductor one part to form a circular conductor structure;

[0012] The insulating layer is coated on the outside of the two conductor parts.

[0013] Furthermore, the second conductor is a copper wire made of oxygen-free copper metal;

[0014] The purity of the copper wire is above 99.99%;

[0015] The number of copper wires is Z, 6 ≤ Z ≤ 19;

[0016] The diameter of a single copper wire is R1, 0.10mm≤R1≤0.20mm.

[0017] Furthermore, the second conductor is made of copper-clad aluminum;

[0018] The volume proportion of copper in the second conductor part is N, 20%≤N≤40%.

[0019] Furthermore, the cross-sectional area of ​​the circular conductor structure is S, 0.13 mm 2 ≤S≤0.22mm 2 .

[0020] Furthermore, the insulation concentricity of the insulation layer is ≥70%;

[0021] The outer diameter of the insulating layer is R2, 0.9 mm ≤ R2 ≤ 1.6 mm;

[0022] The insulating layer is made of polyvinyl chloride, cross-linked polyethylene, fluoroplastic and is formed by an extrusion process;

[0023] The temperature resistance range of the insulation layer is M, -40°C≤M≤200°C;

[0024] The insulating layer has a withstand voltage of 60V.

[0025] In the above technical solution, the utility model of an ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles has the following beneficial effects:

[0026] 1. The central structure of the conductor is made of copper alloy, which increases the overall tensile strength of the cable and improves the bending performance of the cable;

[0027] 2. The conductor wire bundling process can be produced using the existing wire bundling machine without the need for equipment investment;

[0028] 3. The cross section of the wire can be changed from the traditional 0.35mm 2 Down to 0.13-0.22mm 2 , which is beneficial to the lightweight of the wiring harness;

[0029] 4. The overall material consumption of wires is reduced;

[0030] 5. The outer diameter of the wire is reduced, the space occupied by the wiring harness is reduced, and the space occupied in the car is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present utility model. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0032] Figure 1 A schematic diagram of the structure of an ultra-thin-wall high-strength ultra-fine composite cable for new energy vehicles provided by an embodiment of the utility model (the two conductor parts are copper wires made of oxygen-free metal copper);

[0033] Figure 2 A schematic structural diagram of an ultra-thin-wall, high-strength, ultra-fine composite cable for new energy vehicles provided in an embodiment of the utility model (the two conductor parts are made of copper-clad aluminum).

[0034] Description of reference numerals:

[0035] 1. Conductor part 1; 2. Conductor part 2; 3. Insulation layer. DETAILED DESCRIPTION

[0036] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings.

[0037] It should be noted that the terms "external" and the like used in this article to indicate orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description. Similar expressions are only for the purpose of illustration, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0038] See also Figure 1-Figure 2 As shown;

[0039] An ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles, comprising:

[0040] Conductor part 1: Conductor part 1 is made of copper-clad steel;

[0041] Conductor part 2, multiple groups of conductor part 2 are twisted by a wire bundling machine and wrapped around the outside of conductor part 1 to form a circular conductor structure;

[0042] The insulating layer 3 is coated on the outside of the second conductor part 2.

[0043] The second conductor part 2 is a copper wire made of oxygen-free copper metal;

[0044] The purity of copper wire is above 99.99%;

[0045] The number of copper wires is Z, 6 ≤ Z ≤ 19;

[0046] The diameter of a single copper wire is R1, 0.10mm≤R1≤0.20mm.

[0047] The conductor part 2 is made of copper-clad aluminum;

[0048] The volume percentage of copper in the conductor part 2 is N, 20%≤N≤40%.

[0049] The cross-sectional area of ​​the circular conductor structure is S, 0.13mm 2 ≤S≤0.22mm 2 .

[0050] The insulation concentricity of the insulation layer 3 is ≥ 70%;

[0051] The outer diameter of the insulating layer 3 is R2, 0.9 mm ≤ R2 ≤ 1.6 mm;

[0052] The insulating layer 3 is made of polyvinyl chloride, cross-linked polyethylene, or fluoroplastic and is formed by an extrusion process;

[0053] The temperature resistance range of the insulation layer 3 is M, -40℃≤M≤200℃;

[0054] The insulation layer 3 has a withstand voltage of 60V.

[0055] Specifically, the conductor part 1 and the conductor part 2 are arranged in a 1+6 structure and are twisted by a wire bundling machine to form a single circular conductor structure. The central conductor (conductor part 1) is made of copper-clad steel material, and the outer conductor (conductor part 2) is made of oxygen-free metal copper material, generally bare copper, with a purity requirement of more than 99.99% or the outer conductor is made of copper-clad aluminum material, with a copper volume accounting for 20-40%; the conductor part 2 adopts a regular twisted structure, the number of conductors in the conductor part 2 is between 6 and 19, the diameter of the single wire is between 0.10 and 0.20 mm, and the cross-sectional area of ​​the single circular conductor structure is 0.13-0.22 mm 2 ; The insulation layer 3 is made of materials of corresponding temperature grade to ensure the bending performance of the cable, and has the characteristics of oil resistance, hydrolysis resistance, flame retardancy, high temperature resistance (-40℃-200℃), and voltage resistance of 60V; such as PVC, XLPE or FEP, using extrusion process to ensure the roundness of the sheath and easy stripping, the insulation concentricity requirement is ≥70%, and the insulation outer diameter is between 0.9-1.6mm.

[0056] Embodiment 1:

[0057] The central conductor is made of 0.2mm copper-clad steel monofilament;

[0058] The outer conductor is made of annealed bare copper monofilament, twisted in the outer layer of copper-clad steel monofilament, 6 strands (6 x 0.2mm monofilaments) + 0.2mm copper-clad steel structure, twisting pitch 14mm, conductor resistance 92.0Ω / km;

[0059] The insulating layer 3 is made of polyvinyl chloride material, with an outer diameter of 1.1-1.2 mm, a thinnest point of 0.2 mm, and a concentricity of ≥70%.

[0060] The above only describes some exemplary embodiments of the present invention by way of illustration. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles, characterized in that: include: A conductor part (1), wherein the conductor part (1) is made of copper-clad steel; Conductor part two (2), multiple groups of conductor part two (2) are twisted by a wire bundling machine and wrapped around the outside of conductor part one (1) to form a circular conductor structure; An insulating layer (3), the insulating layer (3) is coated on the outside of the second conductor part (2).

2. The ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles according to claim 1, characterized in that: The second conductor part (2) is a copper wire made of oxygen-free copper metal; The purity of the copper wire is above 99.99%; The number of copper wires is Z, 6 ≤ Z ≤ 19; The diameter of a single copper wire is R1, 0.10mm≤R1≤0.20mm.

3. The ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles according to claim 1, characterized in that: The second conductor part (2) is made of copper-clad aluminum; The volume proportion of copper in the second conductor part (2) is N, 20%≤N≤40%.

4. An ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles according to claim 2 or 3, characterized in that: The cross-sectional area of ​​the circular conductor structure is S, 0.13 mm 2 ≤S≤0.22mm 2 .

5. The ultra-thin wall high-strength ultra-fine composite cable for new energy vehicles according to claim 1, characterized in that: The insulation concentricity of the insulating layer (3) is ≥70%; The outer diameter of the insulating layer (3) is R2, 0.9 mm ≤ R2 ≤ 1.6 mm; The insulating layer (3) is made of polyvinyl chloride, cross-linked polyethylene, or fluoroplastic and is formed through an extrusion process; The insulation layer (3) has a temperature resistance range of M, -40°C ≤ M ≤ 200°C; The insulating layer (3) has a withstand voltage of 60V.

Images