Scratch-resistant high-voltage flexible flat cable for new energy automobile

Abstract

The utility model discloses a scratch-resistant high-voltage flexible flat cable for a new energy automobile, which relates to the technical field of cables and comprises a plurality of groups of conductors which are sequentially laid in a straight line shape. The insulating layer wraps the conductor and is of a flat structure. The shielding layer is coated outside the insulating layer; the sheath layer wraps the shielding layer. The wear-resistant layer is coated on the insulating layer or the sheath layer; the plurality of conductors are sequentially arranged in a straight line, the superficial area of the conductors is increased, the heat dissipation performance of the cable is improved, the whole cable adopts a flat structure, the heat dissipation area of the cable is increased, and the long-term operation capability of the cable at high temperature is improved; the insulating layer adopts a flat structure and can be uniformly extruded on the surface of the cable, so that the flexibility of the cable can be improved, and the flexibility is further enhanced; the outermost layer of the cable adopts a wear-resistant layer structure, so that the wear resistance of the cable can be greatly enhanced, and the protection of a wire harness sleeve is not needed; the cable adopts a flat structure, can be directly and stably laid in a vehicle, and does not need to be protected by a plastic cover plate.

Description

Technical Field

[0001] The utility model relates to the technical field of cables, in particular to a scratch-resistant and wear-resistant high-voltage soft flat cable for new energy vehicles. Background Art

[0002] At present, with the rapid development of new energy vehicles in China, the demand for wiring harnesses that play a connecting role inside them has increased greatly. The high-voltage wiring harness technology is difficult. As a key component of the high-voltage electrical system, it provides a guarantee for the operation and safety of new energy vehicles. Its main application range includes the connection harness between the power point output group and the motor, the connection harness between the charging port and the power battery, the connection harness inside the power battery, etc. It connects all high-voltage electronic components and transmits electricity and data, which is extremely important for new energy vehicles.

[0003] As an important part of high-voltage automotive wiring harness, high-voltage cables for new energy vehicles currently still use traditional cable structures. High-voltage cables for new energy vehicles with a temperature resistance of 150 degrees generally use polyolefin materials, but this is far from meeting the temperature resistance requirements of high-voltage cables. High-voltage silicone cables for new energy vehicles with high temperature resistance, although they are excellent in terms of cable softness, temperature resistance, and resistance to chemical liquids, also have the following defects:

[0004] 1. The cable sheath layer is made of a single plastic material, which has poor tear resistance, is not scratch-resistant, and is easily damaged;

[0005] 2. In order to ensure the cable's scratch resistance, a sleeve will be set on the outer surface of the cable, which increases the difficulty of production;

[0006] 3. The cable is circular in structure, which is not stable enough when installed inside the car. It will shake and need to be supported by a cover plate, which takes up too much space inside the car.

[0007] 4. The cable has a circular structure. With the same cross-section, the cable surface area is small, which is not conducive to heat dissipation in a closed space and may cause a breakdown risk;

[0008] Therefore, in view of the problems existing in the high-voltage cable structure traditionally used in new energy vehicles, a high-voltage soft flat cable with optimized structure, high temperature resistance, scratch resistance, good heat dissipation and easy laying is designed to solve the above problems. Summary of the invention

[0009] The utility model aims to provide a scratch-resistant high-voltage soft flat cable for new energy vehicles which has an optimized structure, is resistant to high temperature and scratches, is conducive to heat dissipation, and is easy to lay.

[0010] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0011] A scratch-resistant high-voltage soft flat cable for new energy vehicles, comprising:

[0012] Conductors, wherein a plurality of groups of the conductors are laid in sequence in a straight line;

[0013] An insulating layer, which is coated on the outside of the conductor and has a flat structure;

[0014] A shielding layer, wherein the shielding layer is coated on the outside of the insulating layer;

[0015] A sheath layer, wherein the sheath layer is coated on the outside of the shielding layer;

[0016] The wear-resistant layer is coated on the insulating layer or the sheath layer.

[0017] Further, the conductor is formed by twisting copper wires;

[0018] The copper wire is made of oxygen-free copper or tinned copper;

[0019] The purity of the copper wire is above 99.99%;

[0020] The number of copper wires in the conductor is between 7 and 1200, and the diameter of a single copper wire is between 0.12 and 0.50 mm.

[0021] Furthermore, the insulating layer is made of silicone rubber material and is formed by an extrusion process;

[0022] The insulation concentricity of the insulation layer is ≥80%.

[0023] Further, the shielding layer includes a braided portion and an aluminum-plastic composite tape;

[0024] The braided part is made of oxygen-free metal copper wire with tinned surface and formed by a braiding process;

[0025] The braided portion is externally wound with an aluminum-plastic composite tape;

[0026] The purity of the oxygen-free metal copper wire with tinned surface is above 99.99%.

[0027] Furthermore, the sheath layer is made of silicone rubber material and is formed by an extrusion process;

[0028] The insulation concentricity of the sheath layer is ≥70%.

[0029] Furthermore, the inner layer of the wear-resistant layer is made of polyester yarn and formed by a weaving process;

[0030] The woven surface and gaps of the polyester yarn are coated with flame-retardant silicone organic paint.

[0031] In the above technical solution, the utility model of a scratch-resistant high-voltage soft flat cable for new energy vehicles has the following beneficial effects:

[0032] 1. Multiple groups of conductors are arranged in a straight line in sequence to increase the surface area of ​​the conductors and improve the heat dissipation performance of the cable. The overall cable adopts a flat structure to increase the heat dissipation area of ​​the cable and improve the long-term operation ability of the cable under high temperature;

[0033] 2. The insulating layer adopts a flat structure, which can be evenly squeezed on the cable surface, which can increase the softness of the cable and further enhance its flexibility;

[0034] 3. The outermost layer of the cable adopts a wear-resistant layer structure, which can greatly enhance the wear resistance of the cable and does not require the protection of the harness sleeve;

[0035] 4. The cable adopts a flat structure and can be laid directly in the car. It is laid firmly and does not require the protection of a plastic cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] 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.

[0037] Figure 1 A schematic structural diagram of a scratch-resistant, high-voltage, flexible flat cable (with a shielding structure) for new energy vehicles provided by an embodiment of the utility model;

[0038] Figure 2 A schematic structural diagram of a scratch-resistant, high-voltage, flexible flat cable (without a shielding structure) for new energy vehicles provided in an embodiment of the utility model.

[0039] Description of reference numerals:

[0040] 1. Conductor; 2. Insulation layer; 3. Shielding layer; 4. Sheath layer; 5. Wear-resistant layer. DETAILED DESCRIPTION

[0041] 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.

[0042] It should be noted that the terms "upper", "inner layer", "outer" and the like used in this article to indicate the orientation or position relationship are based on the orientation or position relationship shown in the 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.

[0043] See also Figure 1-Figure 2 As shown;

[0044] A scratch-resistant high-voltage soft flat cable for new energy vehicles, comprising:

[0045] Conductor 1, multiple groups of conductors 1 are laid in sequence in a straight line;

[0046] An insulating layer 2, the insulating layer 2 is coated on the outside of the conductor 1 and has a flat structure;

[0047] A shielding layer 3, wherein the shielding layer 3 is coated on the outside of the insulating layer 2;

[0048] A sheath layer 4, wherein the sheath layer 4 is coated on the outside of the shielding layer 3;

[0049] The wear-resistant layer 5 is coated on the insulating layer 2 or the sheath layer 4 .

[0050] Preferably, a scratch-resistant high-voltage soft flat cable for new energy vehicles, for conductors 1 with different cross-sections, an insulating layer 2, a shielding layer 3, a sheath layer 4, and a wear-resistant layer 5 are sequentially superimposed to form different flat structures, which can enhance the softness of the cable, increase the heat dissipation area of ​​the cable, and be flexible in use;

[0051] The outermost wear-resistant layer 5 of the cable can adopt a double-layer structure, which can greatly enhance the wear resistance of the cable;

[0052] Among them, the cable with shielding structure (see Figure 1 ), that is, a shielding layer 3 is provided, and its wear-resistant layer 5 is coated on the outside of the sheath layer 4; a cable without a shielding structure (see Figure 2 ), that is, the shielding layer 3 is not provided, and the wear-resistant layer 5 is coated on the outside of the insulating layer 2. Both cables are provided with the wear-resistant layer 5 to increase the wear resistance.

[0053] The conductor 1 is formed by twisting copper wires;

[0054] The copper wire is made of oxygen-free copper or tinned copper;

[0055] The purity of copper wire is above 99.99%;

[0056] The number of copper wires in the conductor 1 is between 7 and 1200, and the diameter of a single copper wire is between 0.12 and 0.50 mm.

[0057] The insulating layer 2 is made of silicone rubber material and is formed by an extrusion process;

[0058] The insulation concentricity of the insulation layer 2 is ≥80%.

[0059] The shielding layer 3 comprises a braided portion and an aluminum-plastic composite tape;

[0060] The braided part is made of oxygen-free copper wire with tinned surface and formed by braiding process;

[0061] The outside of the braided part is wrapped with an aluminum-plastic composite tape;

[0062] The purity of the oxygen-free copper wire with tin plating on the surface is above 99.99%.

[0063] The sheath layer 4 is made of silicone rubber material and is formed by an extrusion process;

[0064] The insulation concentricity of the sheath layer 4 is ≥70%.

[0065] The inner layer of the wear-resistant layer 5 is made of polyester yarn and formed by a weaving process;

[0066] The polyester yarn weaving surface and gaps are coated with flame retardant silicone organic paint.

[0067] The specific embodiments are as follows:

[0068] FL2GCB2R 50 cable

[0069] 1. Conductor

[0070] 1) The copper conductor is made of annealed bare copper monofilament;

[0071] 2) 50mm2 conductor structure 3 strands 91 / 0.4mm, conductor resistance 3.3Ω / km;

[0072] 2. Insulation layer

[0073] 1) The insulation layer is made of high-voltage silicone rubber insulation;

[0074] 2) Three round conductors are placed side by side and formed into a square insulation structure through a special extrusion die;

[0075] 3) The outer diameter of the wire core is 7.4*16.2mm, the thinnest point is 1.2mm, and the concentricity is ≥80%;

[0076] 3. Shielding layer

[0077] 1) The shielding layer adopts weaving technology, with weaving wire 0.21mm and weaving density 85%;

[0078] 2) The aluminum-plastic composite tape is 0.03mm thick and wrapped in overlap, with a minimum overlap rate of no less than 25%;

[0079] 4. Sheath layer

[0080] 1) The sheath layer is made of silicone rubber material with a concentricity of ≥80% and is extruded through a special die;

[0081] 2) Sheath outer diameter: 11.4*20.2mm;

[0082] 3) Sheath thickness: 1.2mm~1.6mm;

[0083] 5. Wear-resistant layer

[0084] 1) The wear-resistant layer is woven with polyester yarn, the yarn thickness is 0.21 mm, and the weaving density is 95%;

[0085] 2) The outer surface of the braided layer is coated with flame-retardant silicone organic paint, and the coating thickness is 0.2mm;

[0086] 3) Outer diameter: 12.4*21.1mm.

[0087] 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. A scratch-resistant high-voltage soft flat cable for new energy vehicles, characterized in that: include: Conductors (1), wherein a plurality of groups of the conductors (1) are laid out in sequence in a straight line; An insulating layer (2), the insulating layer (2) is coated on the outside of the conductor (1) and has a flat structure; A shielding layer (3), wherein the shielding layer (3) is coated on the outside of the insulating layer (2); A sheath layer (4), the sheath layer (4) being coated on the outside of the shielding layer (3); A wear-resistant layer (5), wherein the wear-resistant layer (5) is coated on the insulating layer (2) or the sheath layer (4).

2. The scratch-resistant high-voltage soft flat cable for new energy vehicles according to claim 1, characterized in that: The conductor (1) is formed by twisting copper wires; The copper wire is made of oxygen-free copper or tinned copper; The purity of the copper wire is above 99.99%; The number of copper wires in the conductor (1) is between 7 and 1200, and the diameter of a single copper wire is between 0.12 and 0.50 mm.

3. The scratch-resistant high-voltage soft flat cable for new energy vehicles according to claim 1, characterized in that: The insulating layer (2) is made of silicone rubber material and is formed through an extrusion process; The insulation concentricity of the insulation layer (2) is ≥80%.

4. The scratch-resistant high-voltage soft flat cable for new energy vehicles according to claim 1, characterized in that: The shielding layer (3) comprises a braided portion and an aluminum-plastic composite tape; The braided part is made of oxygen-free metal copper wire with tinned surface and formed by a braiding process; The braided portion is externally wound with an aluminum-plastic composite tape; The purity of the oxygen-free metal copper wire with tinned surface is above 99.99%.

5. The scratch-resistant high-voltage soft flat cable for new energy vehicles according to claim 1, characterized in that: The sheath layer (4) is made of silicone rubber material and is formed through an extrusion process; The insulation concentricity of the sheath layer (4) is ≥70%.

6. The scratch-resistant high-voltage soft flat cable for new energy vehicles according to claim 1, characterized in that: The inner layer of the wear-resistant layer (5) is made of polyester yarn and is formed by a weaving process; The woven surface and gaps of the polyester yarn are coated with flame-retardant silicone organic paint.

Images