Vehicle-mounted light alternating current charging wire

Abstract

The utility model relates to the technical field of charging wires, in particular to a vehicle-mounted light alternating current charging wire. Comprising a plurality of power lines and signal lines which are tightly twisted, a wrapping tape layer and an outer coating layer which wrap the power lines and the signal lines, and filling strips which are filled in gaps between the power lines and the wrapping tape layer, each power line comprises an aluminum alloy conductor and an irradiation cross-linked polyolefin insulating layer which wraps the aluminum alloy conductor, and the irradiation cross-linked polyolefin insulating layer wraps the aluminum alloy conductor. The number of the aluminum alloy conductors is 105-110, and the diameter of the aluminum alloy conductors is 0.3-0.35 mm. The specific gravity of the aluminum alloy conductor is only 30% of that of copper, the weight of the whole wire can be reduced by about 50%, so that the wire is light, the application of the wire is more convenient, the wire can better meet the vehicle-mounted use condition, the irradiation cross-linked polyolefin insulating layer can ensure that the long-term operation temperature of the wire reaches 125 DEG C, the service life of the wire is prolonged, and the allowable current of the wire is improved; and due to the high flexibility, the wire rod has a smaller bending radius, the service life of the wire rod in repeated bending application is prolonged, and the wire rod can be better stored and charged in vehicle-mounted use.

Description

Technical Field

[0001] The present application relates to the technical field of charging cables, and in particular to a lightweight AC charging cable for a vehicle. Background Art

[0002] With the rapid development of new energy vehicles, the charging problem of new energy vehicles has become the focus of attention in recent years. At present, the charging methods of new energy vehicles are mainly divided into DC fast charging and AC slow charging. DC fast charging is mostly used in public charging stations, while AC slow charging is mostly used as a private charging method. At present, both DC and AC charging cables are mainly copper cables, which are relatively expensive and have a large overall weight. When the cables need to be used with the vehicle, it causes inconvenience in the use and transportation process. Utility Model Content

[0003] In order to solve the above technical problems, the present application provides a lightweight AC charging cable for on-board use, comprising a number of tightly twisted power lines and signal lines, a tape layer and an outer layer coated on the power lines and signal lines, and a filling strip filled in the gap between the power lines and the tape layer, wherein the power line comprises an aluminum alloy conductor and an irradiated cross-linked polyolefin insulation layer coated with the aluminum alloy conductor, wherein the number of the aluminum alloy conductors is 105-110 and the diameter is 0.3-0.35 mm. The specific gravity of the aluminum alloy conductor is only 30% of that of copper, which can reduce the weight of the entire line by about 50%, thereby achieving lightweight wire, making it more convenient to use and more in line with the conditions for on-board use, and the irradiated cross-linked polyolefin insulation layer can ensure that the long-term operating temperature of the wire reaches 125°C, prolong the life of the wire, and increase the allowable current of the wire. Its high flexibility can achieve a smaller bending radius for the wire, improve its life in repeated bending applications, and facilitate better storage and charging of the wire in on-board use.

[0004] Preferably, the signal line includes a plurality of copper foil wires, a tinned copper conductor surrounding the outer periphery of the copper foil wires, and a signal insulation layer covering the outer periphery of the tinned copper conductor.

[0005] Preferably, the number of the copper foil wires is 7 and they are twisted concentrically to form a double-layer structure, with the center layer having 1 copper foil wire and the outer layer having 6 copper foil wires.

[0006] Preferably, the copper foil wire and the tinned copper conductor have a diameter of 0.23-0.25 mm.

[0007] Preferably, the twist pitch ratio of the plurality of power lines and signal lines is 14-15.

[0008] Preferably, the wrapping layer is formed by wrapping a paper tape with a thickness of 0.04-0.05 mm.

[0009] Preferably, the filling strip is polyester fiber.

[0010] As can be seen from the above, the following beneficial effects can be obtained by applying the present application: by designing 105 aluminum alloy conductors to be bundled and twisted at one time, the softness of the wire can be improved, and it has very good creep resistance. The tensile strength of the aluminum alloy conductor single wire is above 160MPa, which meets the requirements of power transmission and breaking force. The specific gravity of the traditional copper conductor is 8.89g / cm3, and the specific gravity of the aluminum alloy conductor is only 2.7g / cm3. The specific gravity of the aluminum alloy conductor is only 30% of that of copper, which can reduce the weight of the entire line by about 50%, thereby achieving lightweight wire, making it more convenient to use, and more in line with the conditions of on-board use. The irradiated cross-linked polyolefin insulation layer can ensure that the long-term operating temperature of the wire reaches 125°C, prolong the life of the wire, and increase the allowable current of the wire. Its high flexibility can achieve a smaller bending radius for the wire, improve its life in repeated bending applications, and facilitate better storage and charging of the wire in on-board use. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings required for use in the description of the embodiments of the present application or the prior art are briefly introduced below. Obviously, the drawings described below are only part of the embodiments of the present application, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor.

[0012] Figure 1 This is a schematic diagram of the structure of a lightweight AC charging cable for a vehicle according to an embodiment of the present application. DETAILED DESCRIPTION

[0013] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0014] Example

[0015] In order to solve the above technical problems, this embodiment provides a lightweight AC charging cable for vehicle use, such as Figure 1As shown, it includes a plurality of tightly twisted power lines 10 and signal lines 20, a tape layer 50 and an outer layer 40 covering the power lines 10 and the signal lines 20, and a filling strip 30 filling the gap between the power lines 10 and the tape layer 50. The power line 10 includes an aluminum alloy conductor 11 and an irradiated cross-linked polyolefin insulation layer 12 covering the aluminum alloy conductor 11. The number of aluminum alloy conductors 11 is 105-110, and the diameter is 0.3-0.35 mm. By designing 105 aluminum alloy conductors 11 with a diameter of 0.3 mm to be twisted in one bundle, the softness of the wire is improved, and the power transmission requirements are met while having very good creep resistance. The tensile strength of the single wire of the aluminum alloy conductor 11 is above 160 MPa, which meets the breaking force requirements. The specific gravity of traditional copper conductors is 8.89g / cm3, while the specific gravity of aluminum alloy conductors 11 is only 2.7g / cm3, which is only 30% of that of copper. The weight of the entire wire can be reduced by about 50%, thereby achieving lightweight wires, making their application more convenient and more suitable for on-board use. The irradiated cross-linked polyolefin insulation layer 12 can ensure that the long-term operating temperature of the wire reaches 125°C, prolong the life of the wire, and increase the allowable current of the wire. Its high flexibility can achieve a smaller bending radius for the wire, thereby increasing its life in repeated bending applications and facilitating better storage and charging of the wire during on-board use.

[0016] Specifically, the radiation cross-linked polyolefin elastomer used in the radiation cross-linked polyolefin insulation layer 12 can increase the long-term operating temperature of the insulation to 125°C after radiation cross-linking, which fully meets the ambient temperature in the application and the temperature rise generated by the conductor during wire operation. In addition, after radiation cross-linking, the softness and chemical resistance of the insulation layer are significantly improved, which can increase the service life of the wire. It is convenient for the wire to be better stored in the vehicle and has a smaller bending radius during charging applications. Among them, the cross-sectional area of ​​105 aluminum alloy conductors 11 after being twisted into a bundle is 8mm 2 Its allowable working current is equivalent to that of 6mm2 copper wire. The 6000 series aluminum alloy conductor 11 used has a tensile strength close to that of copper conductor, and the terminal can be directly crimped when matched with the charging gun.

[0017] Charging confirmation is required when the car is charging, so a signal line 20 needs to be set in the wire. When the wire is actually used, external forces such as bending, moving, and pulling will act on the internal core wire, and the internal power line stress will also act on the signal line 20, so the mechanical strength requirements for the conductor of the signal line 20 become higher. To this end, the signal line 20 includes a plurality of twisted copper foil wires 21, a tinned copper conductor 22 wrapped around the outer periphery of the copper foil wire 21, and a signal insulation layer 23 wrapped around the outer periphery of the tinned copper conductor 22. The twisted copper foil wire 21 has ultra-high strength and can withstand most external forces, thereby better protecting the outermost tinned copper conductor 22 as the main current transmission, thereby improving the safety and reliability of the signal line. The signal insulation layer 23 uses a radiation cross-linked polyolefin material with a hardness of 95A, which can further improve the mechanical strength of the signal line.

[0018] Specifically, the number of copper foil wires 21 is 7 and they are twisted concentrically to form a double-layer structure, with 1 copper foil wire 21 in the center layer and 6 copper foil wires 21 in the outer layer. The cross-sectional area of ​​the tinned copper conductor 22 is 0.75 mm2, and the diameters of the copper foil wires 21 and the tinned copper conductors 22 are 0.23-0.25 mm. The outer periphery of the outer copper foil wire 21 is 12 tinned copper conductors 22, and the diameters of the copper foil wires 21 and the tinned copper conductors 22 are 0.23 mm. This structure is round and soft after twisting, has better resistance to pulling and bending, has ultra-high strength, can withstand most external forces, thereby protecting the tin copper conductor 22, thereby improving the safety and reliability of the signal line.

[0019] In the above scheme, the twisted pitch ratio of the power lines 10 and the signal line 20 is 14-15. Specifically, there are 3 power lines 10 and 1 signal line 20, wherein the 3 power lines are used as the positive electrode, the negative electrode, and the ground line respectively, and the 1 signal line 20 is mainly used for charging confirmation signal feedback, and the twisted pitch ratio of the 3 power lines 10 and the 1 signal line 20 is 14, and the 14-fold twisted pitch ratio makes the wire material more flexible.

[0020] The tape layer 50 is formed by wrapping a paper tape with a thickness of 0.04-0.05 mm, so that the twisted power cord 10 and the signal line 20 are tied tightly and their structure is stable and flexible. The filling strip 30 in the gap between the power cord 10 and the tape layer 50 is polyester fiber. The high-strength polyester fiber material allows the wire to withstand more tension when bent or pulled, thereby protecting the internal core wire.

[0021] The outer layer 40 is made of a modified thermoplastic elastomer with a hardness of 80A, which has the softness of an elastomer and has a temperature resistance of -40°C to 105°C through modified materials, meeting its daily application conditions. In addition, it meets the environmental protection requirements of ROHS and REACH, does not contain halogen, and will be safer and more environmentally friendly in application.

[0022] In summary, the present application scheme is to set up a number of tightly twisted power lines and signal lines. The power lines include an aluminum alloy conductor and an irradiated cross-linked polyolefin insulation layer covering the aluminum alloy conductor. The number of aluminum alloy conductors is 105-110, and the diameter is 0.3-0.35mm. By designing 105 aluminum alloy conductors to be bundled and twisted at one time, the softness of the wire is improved, and it has very good creep resistance. The tensile strength of the single wire of the aluminum alloy conductor is above 160MPa, which meets the requirements of power transmission and the breaking force requirements. The specific gravity of traditional copper conductors is 8.89g / cm3, while that of aluminum alloy conductors is only 2.7g / cm3. The specific gravity of aluminum alloy conductors is only 30% of that of copper, which can reduce the weight of the entire line by about 50%, thereby achieving lightweight wires, making their application more convenient and more in line with the conditions for on-board use. The irradiated cross-linked polyolefin insulation layer can ensure that the long-term operating temperature of the wire reaches 125°C, prolonging the life of the wire and increasing the allowable current of the wire. Its high flexibility can achieve a smaller bending radius for the wire, thereby increasing its life in repeated bending applications and facilitating better storage and charging of the wire during on-board use.

[0023] The above-described implementation methods do not constitute a limitation on the protection scope of the technical solution. Any modification, equivalent replacement and improvement made within the spirit and principle of the above-described implementation methods shall be included in the protection scope of the technical solution.

Claims

1. A lightweight AC charging cable for a vehicle, characterized in that: The invention comprises a plurality of tightly twisted power lines (10) and signal lines (20), a tape layer (50) and an outer layer (40) covering the power lines (10) and the signal lines (20), and a filling strip (30) filling the gap between the power lines (10) and the tape layer (50); the power line (10) comprises an aluminum alloy conductor (11) and a radiation cross-linked polyolefin insulation layer (12) covering the aluminum alloy conductor (11); the number of the aluminum alloy conductors (11) is 105-110 and the diameter is 0.3-0.35 mm.

2. The vehicle-mounted lightweight AC charging cable according to claim 1 is characterized in that: The signal line (20) comprises a plurality of twisted copper foil wires (21), a tinned copper conductor (22) surrounding the outer periphery of the copper foil wires (21), and a signal insulation layer (23) covering the outer periphery of the tinned copper conductor (22).

3. The vehicle-mounted lightweight AC charging cable according to claim 2, characterized in that: The number of the copper foil wires (21) is 7 and they are twisted concentrically to form a double-layer structure, the central layer is 1 copper foil wire (21), the outer layer is 6 copper foil wires (21), and 12 tinned copper conductors (22) are wrapped around the outer layer of the copper foil wires (21).

4. The vehicle-mounted lightweight AC charging cable according to claim 3 is characterized in that: The copper foil wire (21) and the tinned copper conductor (22) have a diameter of 0.23-0.25 mm.

5. The vehicle-mounted lightweight AC charging cable according to claim 1, characterized in that: The twisted pitch ratio of the plurality of power lines (10) and signal lines (20) is 14-15.

6. The vehicle-mounted lightweight AC charging cable according to claim 1, characterized in that: The wrapping tape layer (50) is formed by wrapping a paper tape with a thickness of 0.04-0.05 mm.

7. The vehicle-mounted lightweight AC charging cable according to claim 1, characterized in that: The filling strip (30) is made of polyester fiber.

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