New energy automobile high-voltage shielding cable suitable for full-automatic production line

Abstract

The utility model relates to the technical field of automobile cables, in particular to a high-voltage shielding cable for a new energy automobile, which is suitable for a full-automatic production line and comprises a conductor, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside. The conductor is formed by stranding strand units in a 1 + 6 + 12 layered form; the stranding direction of the second layer of conductor and the third layer of conductor is the left stranding direction; each plied yarn unit is formed by a plurality of plied yarn monofilaments through one-time bunch stranding, and the stranding direction is the right stranding direction; the whole conductor is stranded by using a constant tension control 100% back-twist cage stranding machine; the insulating layer wraps the outer side of the conductor; the shielding layer comprises a tinned copper wire braid layer attached to the insulating layer and a hot melting self-adhesion aluminum foil mylar tape layer on the outer side of the tinned copper wire braid layer; the hot-melting self-adhesion aluminum foil mylar tape layer is a composite material layer and specifically comprises an aluminum foil layer, a PET polyester film layer and an EAA hot-melting film which are arranged from inside to outside; the sheath layer wraps the outer side of the shielding layer. The cable has the advantages of good flexibility, good temperature resistance, wear resistance, vibration resistance and bending resistance.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile cables, and in particular to a high-voltage shielded cable for new energy vehicles suitable for a full-automatic production line. Background Art

[0002] As the new energy electric vehicle market continues to expand, automobile manufacturers have increasing requirements for the production efficiency and quality of automotive wiring harnesses. The stability and efficiency of high-voltage shielded cable processing for new energy vehicles is of utmost importance, and the requirements for production equipment and cables are also getting higher and higher.

[0003] At present, in order to improve production efficiency and stability, the automatic production line of high-voltage shielded cables for new energy vehicles has increasingly stringent requirements for cables. The current mainstream automatic production line equipment uses laser sintering and cutting for the aluminum-plastic composite tape layer in the shielding layer. However, in order to ensure good shielding performance, the aluminum-plastic composite tape is processed by a wrapping process with an overlap rate greater than 20%, which also leads to the inconvenience of laser sintering aluminum foil. The power of the laser is difficult to control. When sintering aluminum foil at a single-layer power, it is easy to produce problems such as failure to sinter and inability to remove the aluminum foil at the overlap position. If the laser power is increased, it is easy to damage the braided wire and the insulation layer. This adds a certain degree of difficulty to the implementation of the fully automatic production line of new energy high-voltage shielded wire harnesses. Utility Model Content

[0004] In view of the defects of the prior art, the utility model proposes a high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line.

[0005] The utility model is achieved in this way:

[0006] A high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line, comprising a conductor, an insulating layer, a shielding layer, and a sheath layer arranged in sequence from the inside to the outside; the conductor is composed of strand units twisted in a layered form of 1+6+12: the first layer conductor includes 1 strand unit; the second layer conductor includes 6 strand units wrapped around the outside of the first layer conductor, and the second layer conductor is twisted in a left direction; the third layer conductor includes 12 strand units wrapped around the outside of the second layer conductor, and the second and third layers of conductors are twisted in a left direction; each strand unit is formed by a plurality of strands of monofilaments being twisted in a bundle once, and the twisting direction is right; the entire conductor is twisted using a 100% back-twisting cage twisting machine with constant tension control;

[0007] The insulating layer is wrapped around the outside of the conductor;

[0008] The shielding layer includes a tinned copper wire braided layer arranged in contact with the insulating layer and a hot-melt self-adhesive aluminum foil Mylar tape layer on its outer side; the hot-melt self-adhesive aluminum foil Mylar tape layer is a composite material layer, specifically including an aluminum foil layer, a PET polyester film layer and an EAA hot-melt film arranged from the inside to the outside;

[0009] The sheath layer is wrapped around the outside of the shielding layer.

[0010] Furthermore, the twisted pitch ratio of the second layer conductor is 17 to 20 times.

[0011] Furthermore, the twisted pitch ratio of the third layer conductor is 16-18 times.

[0012] Furthermore, the twisted pitch-diameter ratio of each strand unit is 26-30 times.

[0013] Furthermore, the strand unit is a copper wire with a diameter of 0.2 mm.

[0014] Furthermore, the insulating layer is made of XLPO material.

[0015] Furthermore, the tinned copper wire braided layer is woven from single-filament tinned copper wires with a diameter of 0.20 mm.

[0016] Furthermore, the braiding density of the tinned copper wire braided layer is ≥85%.

[0017] Furthermore, the hot-melt self-adhesive aluminum foil Mylar tape layer is formed by wrapping, and the wrapping overlap rate is ≥20%.

[0018] Furthermore, the sheath layer is made of XLPO material.

[0019] The utility model has the following advantages and technical effects:

[0020] The hot-melt self-adhesive aluminum foil Mylar tape layer in the shielding layer of the utility model is composited with a layer of aluminum foil + a layer of PET polyester film + EAA hot-melt film. The EAA hot-melt film can be tightly bonded to the sheath layer when heated to about 85°C, and the sheath layer XLPO is a thermoplastic material. The sheath is plasticized by a screw during processing, and extruded through a fixed mold through a high-temperature machine head. The extrusion temperature is about 150-180°C. Therefore, during the sheath extrusion processing, the hot-melt self-adhesive aluminum foil Mylar tape can be directly tightly bonded to the sheath, which is convenient for processing. When processing the wire harness, this product can realize one-time cutting of the hot-melt self-adhesive aluminum foil Mylar tape layer and the sheath layer, avoiding the problem of unstable laser sintering processing, directly eliminating the laser sintering process, and improving both the processing efficiency and the stability of the wire harness processing.

[0021] In addition to the above advantages, this conductor cable can also:

[0022] 1. The cable conductor is made of 0.2mm copper wire, which is soft. After the copper wire is bundled into strands, it is twisted into multiple strands in a 1+6+12 structure using cage twisting. The conductor surface is round and not easy to loosen, which can reduce the resistance loss of the conductor and improve the conductivity of the conductor.

[0023] 2. This cable adopts fixed structural parameter design, cage twisting, the conductor is round and tight, and 100% back-twisting eliminates the residual stress inside the conductor during the twisting process, making the cable have good vibration resistance.

[0024] 3. The overlapping positions of the shielding layers of this cable can be tightly bonded together to achieve a better shielding effect.

[0025] 4. This cable uses XLPO as the cable sheath, which has good wear resistance.

[0026] In summary, the cable has good softness, good temperature resistance, and is wear-resistant, vibration-resistant, and bending-resistant. It can better facilitate the processing of new energy vehicle cables and is better suitable for the fully automatic processing production line of new energy vehicle shielded cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic cross-sectional view of the high-voltage shielded cable of the utility model.

[0028] In the figure: 1, conductor; 1-1, strand unit; 1-2, strand monofilament; 2, insulation layer; 3, shielding layer; 3-1, tinned copper wire braided layer; 3-2, hot-melt self-adhesive aluminum foil Mylar tape layer; 4, sheath layer. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical solution and advantages of the utility model more clear, the utility model is further described in detail in combination with the embodiments below. It should be understood that the specific embodiments described here are only used to explain the utility model, and are not used to limit the utility model.

[0030] like Figure 1 As shown, the utility model discloses a high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line, comprising a conductor, an insulating layer, a shielding layer, and a sheath layer arranged in sequence from the inside to the outside;

[0031] The conductor is composed of strand units twisted in a layered form of 1+6+12: the first layer conductor includes 1 strand unit; the second layer conductor includes 6 strand units wrapped around the outside of the first layer conductor, the second layer conductor has a twisting pitch ratio of 17 to 20 times and is left-twisted; the third layer conductor includes 12 strand units wrapped around the outside of the second layer conductor, the third layer conductor has a twisting pitch ratio of 16 to 18 times and is left-twisted. Each strand unit is formed by a plurality of strands of monofilaments twisted in one bundle, the twisting pitch ratio is 26 to 30 times and is right-twisted; the entire conductor is twisted using a constant tension controlled 100% back-twisting cage twisting machine, which eliminates the twisting tension of the monofilaments, and the strand pitch is uniform after twisting.

[0032] Preferably, the strand unit is a copper wire with a diameter of 0.2 mm and a breaking elongation of the copper wire of 22-30%.

[0033] Preferably, the insulating layer is wrapped around the outside of the conductor, and preferably, the insulating layer is made of XLPO material, which has good flexibility, good insulation, good high temperature resistance and is easy to process.

[0034] The shielding layer includes a tinned copper wire braided layer arranged in contact with the insulating layer and a hot-melt self-adhesive aluminum foil Mylar tape layer on its outer side. The tinned copper wire braided layer is woven from single-filament tinned copper wire with a diameter of 0.20 mm; the single-filament elongation at break is 21-30%, and the braiding density is ≥85%. The hot-melt self-adhesive aluminum foil Mylar tape layer is a composite material layer, which is formed by wrapping, specifically including an aluminum foil layer, a PET polyester film layer and an EAA hot-melt film arranged from the inside to the outside, and the wrapping processing overlap rate is ≥20%.

[0035] The tinned copper wire braided layer has good flexibility and can adapt to the bending and stretching deformation of the cable. However, due to the gaps in the braided copper mesh, it cannot completely shield the interference signal. The shielding method of tinned copper wire braided shielding + aluminum-plastic composite tape wrapping is adopted, which can maintain a certain bending performance while enhancing the shielding effect.

[0036] The hot-melt self-adhesive aluminum foil Mylar tape layer can be tightly bonded to the sheath layer when heated to about 85°C, thereby achieving a better shielding effect. At the same time, when used on the fully automatic processing production line of new energy vehicle wiring harnesses, the sheath layer and the hot-melt self-adhesive aluminum foil Mylar tape layer can be cut at one time, avoiding the problem of residual aluminum foil overlapping position when the production line laser cuts aluminum foil due to the wrapping problem of traditional aluminum-plastic composite tape, and is more suitable for the fully automatic production line of new energy vehicle high-voltage wiring harnesses.

[0037] The sheath layer is wrapped around the outside of the shielding layer and is made of XLPO material, which has higher tensile strength, better heat resistance and wear resistance than materials such as silicone rubber. The sheath layer is plasticized by a screw during processing, and extruded through a fixed mold through a high-temperature die head. The extrusion temperature is about 150-180°C, so the hot-melt self-adhesive aluminum foil Mylar tape can be directly and tightly bonded to the sheath during the sheath extrusion process, which is convenient for processing.

[0038] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line, comprising a conductor, an insulating layer, a shielding layer, and a sheath layer arranged in sequence from the inside to the outside; characterized in that: The conductor is composed of strand units twisted in a layered form of 1+6+12: the first layer conductor includes 1 strand unit; the second layer conductor includes 6 strand units wrapped around the outside of the first layer conductor, and the second layer conductor is twisted in a left direction; the third layer conductor includes 12 strand units wrapped around the outside of the second layer conductor, and the second and third layers of conductors are twisted in a left direction; each strand unit is formed by a plurality of strands of monofilaments being twisted in a bundle once, and the twisting direction is right; the entire conductor is twisted using a constant tension controlled 100% back-twisting cage twisting machine; The insulating layer is wrapped around the outside of the conductor; The shielding layer includes a tinned copper wire braided layer arranged in contact with the insulating layer and a hot-melt self-adhesive aluminum foil Mylar tape layer on its outer side; the hot-melt self-adhesive aluminum foil Mylar tape layer is a composite material layer, specifically including an aluminum foil layer, a PET polyester film layer and an EAA hot-melt film arranged from the inside to the outside; The sheath layer is wrapped around the outside of the shielding layer.

2. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The twisted pitch ratio of the second layer conductor is 17 to 20 times.

3. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The twisted pitch ratio of the third layer conductor is 16-18 times.

4. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The twisted pitch-diameter ratio of each strand unit is 26-30 times.

5. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The strand unit is a copper wire with a diameter of 0.2 mm.

6. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The insulating layer is made of XLPO material.

7. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The tinned copper wire braided layer is braided with single-filament tinned copper wires with a diameter of 0.20 mm.

8. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 7, characterized in that: The braiding density of the tinned copper wire braided layer is ≥85%.

9. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The hot-melt self-adhesive aluminum foil Mylar tape layer is formed by wrapping, and the wrapping processing overlap rate is ≥20%.

10. The high-voltage shielded cable for new energy vehicles suitable for a fully automatic production line according to claim 1, characterized in that: The sheath layer is made of XLPO material.

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