Ultra-soft low-voltage aluminum conductor cable for new energy automobile

Abstract

The utility model relates to the technical field of automobile cables, in particular to an ultra-soft low-voltage aluminum conductor cable for a new energy automobile, which comprises a conductor and an insulating layer which are sequentially arranged from inside to outside. The conductor is formed by 100% complete back-twist stranding of 12 strands in a 3 + 9 layered form through a cage stranding machine, and the conductor comprises 3 strands of inner-layer strands and 9 strands of outer-layer strands uniformly arranged on the peripheries of the inner-layer strands; the stranding pitch diameter ratio of the three inner-layer strands is 22-25 times and is in the left stranding direction, and the stranding pitch diameter ratio of the nine outer-layer strands is 15-17 times and is in the left stranding direction; all the strands are formed by stranding aluminum monofilaments with the same number in a bunch mode, and the stranding direction is leftward; each inner-layer stranded wire and each outer-layer stranded wire comprise 5 inner-layer aluminum monofilaments and 11 outer-layer aluminum monofilaments which are uniformly arranged on the peripheries of the inner-layer aluminum monofilaments; the pitch diameter ratio of each plied yarn is 25-30 times, and each plied yarn is twisted leftwards; the insulating layer wraps the outer side of the conductor. The cable provided by the utility model has high flexibility, is easy to bend and shape, and provides convenience for wire harness processing and whole vehicle wiring installation.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile cables, in particular to an ultra-soft low-voltage aluminum conductor cable for new energy vehicles. Background Art

[0002] As the new energy electric vehicle market continues to expand, the use of aluminum conductor cables has also increased. In order to meet consumers' requirements for vehicle space and comfort, car designers are also paying more and more attention to the rationality of the wiring harness space layout and wiring position arrangement in the car. This requires aluminum conductor cables to have high flexibility, appropriate bending radius, and excellent processing and installation performance, so as to meet the current development needs of the new energy market.

[0003] However, due to the material problem, the diameter of aluminum conductor single wire is generally thicker than that of copper single wire, and the surface smoothness is worse than that of copper conductor. Therefore, the bending performance is worse than that of copper conductor cable, which brings difficulties to the wiring harness processing and vehicle assembly. Utility Model Content

[0004] In view of the defects of the prior art, the utility model proposes an ultra-soft low-voltage aluminum conductor cable for new energy vehicles, which solves the problem that the application of aluminum conductor cables is limited due to poor cable bending performance.

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

[0006] A super-soft low-voltage aluminum conductor cable for new energy vehicles, comprising a conductor and an insulating layer arranged in sequence from the inside to the outside; the conductor is formed by 12 strands of wire being twisted 100% completely in a 3+9 layered form by a cage stranding machine, specifically, the conductor comprises 3 inner strands and 9 outer strands of wire evenly arranged on the outer periphery of the inner strands; wherein the twisting pitch-diameter ratio of the 3 inner strands is 22 to 25 times and is left-twisted, and the twisting pitch-diameter ratio of the 9 outer strands is 15 to 17 times and is left-twisted;

[0007] All strands are composed of an equal number of aluminum monofilaments in a bundle twisted manner, and the twisting direction is left-handed; specifically, each inner and outer layer strand includes 5 inner layer aluminum monofilaments and 11 outer layer aluminum monofilaments evenly arranged on the periphery of the inner layer aluminum monofilaments; each of the strands has a pitch-diameter ratio of 25 to 30 times and is left-twisted;

[0008] The insulating layer is wrapped around the outside of the conductor.

[0009] Furthermore, the grade of the aluminum monofilament is AW-1370.

[0010] Furthermore, the conductor cross section is 40 mm 2 .

[0011] Furthermore, the diameter of the aluminum monofilament ranges from 0.49 mm to 0.50 mm.

[0012] Furthermore, the twisting pitch of each strand is 55-65 mm.

[0013] Furthermore, the twisting pitches of the three inner strands are all 100-110 mm.

[0014] Furthermore, the twisting pitches of the 9 outer strands are all 120-130 mm.

[0015] Furthermore, the insulating layer is a silicone rubber layer, and the silicone rubber material has a hardness of 63±2 degrees.

[0016] Furthermore, the tensile strength of the aluminum filament bundle is 80 to 100 MPa.

[0017] Furthermore, the elongation of the aluminum filament bundle is 20% to 30%.

[0018] The utility model has the following advantages and technical effects:

[0019] The conductor cable proposed by the utility model adopts a specific 3+9 layered twisted structure of strands and 5+11 bundle-twisted aluminum monofilaments; and the strands are twisted by a cage twisting machine with 100% complete back-twisting. The above specific twisted structure and twisting method can eliminate the stress of the strands caused by the twisting and unwinding when the strands are twisted. After twisting, the pitch of the strands is uniform, so that the conductor has better vibration resistance and bending resistance.

[0020] Silicone rubber is used as the insulating material, which has good resistance to high and low temperatures, making the finished cable more flexible and suitable for more stringent wiring environments.

[0021] In summary, the conductor cable has high flexibility, better temperature resistance, and is resistant to vibration and bending. It can better facilitate the processing of new energy vehicle cables and is better suited to the harsh wiring environment of new energy vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic cross-sectional view of the conductor cable of the present invention.

[0023] In the figure: 1, conductor; 1-1, inner strand; 1-2, outer strand; 1-3, aluminum monofilament; 2, insulation layer. DETAILED DESCRIPTION

[0024] 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.

[0025] like Figure 1 As shown, the utility model discloses an ultra-soft low-voltage aluminum conductor cable for new energy vehicles, comprising a conductor 1 and an insulating layer 2 arranged in sequence from the inside to the outside;

[0026] The conductor 1 is formed by 12 strands of wires twisted in a 3+9 layered form by a cage stranding machine with 100% complete back-twisting. Specifically, the conductor includes 3 inner strands 1-1 and 9 outer strands 1-2 evenly arranged on the outer periphery of the inner strands; wherein the twisting pitch-diameter ratio of the 3 inner strands is 22 to 25 times and is left-twisted, and the twisting pitch-diameter ratio of the 9 outer strands is 15 to 17 times and is left-twisted.

[0027] All strands are composed of equal numbers of aluminum monofilaments in a bundle twisted manner; each strand has a pitch-diameter ratio of 25 to 30 times and is left-twisted; specifically, the inner and outer strands include 5 inner aluminum monofilaments 1-3 and 11 outer aluminum monofilaments 1-3 evenly arranged on the periphery of the inner aluminum monofilaments; in this embodiment, the aluminum monofilaments are AW-1370 grade. 2 Take the conductor of as an example, each conductor is made of 192 aluminum monofilaments with a diameter of 0.5mm, and the diameter of the aluminum monofilaments ranges from 0.49mm to 0.50mm. The first bundle twisting is carried out first, that is, 16 aluminum monofilaments are made into strands in a bundle twisted manner, the twisting direction is left-handed, and the pitch is 55-65mm; after the 12 strands are made, a cage twisting machine is used to twist them 100% completely back-twisted in a 3+9 layered form to make a conductor; all are twisted by a cage twisting machine 100% completely back-twisted, which can eliminate the stress of the strands caused by the twisting and unwinding, and the strand pitch is uniform after twisting. The twisted pitch of the 3 inner strands is 100-110mm, and the twisted pitch of the 9 outer strands is 120-130mm. After the entire conductor is twisted, it is annealed as a whole to eliminate the internal stress of the monofilament. After annealing, the tensile strength of the monofilament is 80-100MPa and the elongation is 20%-30%. Through the specific twisting structure design and twisting parameter design of the above-mentioned conductor, not only can the conductor have better bending performance, but also the process route of twisting first and then annealing can reduce the problem of surface scratches on the single wire during the twisting process due to the soft aluminum material. It can also more stably control the mechanical properties of the aluminum conductor single wire, so that the conductor single wire maintains good bending resistance, and the conductor has excellent characteristics such as softness, bending resistance, and vibration resistance.

[0028] like Figure 1As shown, the insulating layer 2 is a silicone rubber layer, which is wrapped around the outside of the conductor. The silicone rubber layer is an insulating layer formed by the curing or vulcanization mechanism of silicone rubber. The vulcanizing agent causes the silicone rubber to undergo a cross-linking reaction during the curing process to form an elastic solid. Silicone rubber insulation is widely used in new energy vehicle cables because it has better high and low temperature resistance, and the material is soft and has low hardness. Using it as an insulating layer to make cables has better bending performance.

[0029] This implementation case uses a silicone rubber material with a hardness (Shore A) of 63±2 degrees. The silicone rubber insulation is extruded by cold extrusion, and after extrusion, it is vulcanized and formed in a one-time process in a vulcanizing furnace. The extrusion barrel and the extruder are both cooled by circulating coolant to keep the extrusion temperature constant, reduce scorching, and vulcanize early. The extrusion uses a semi-extrusion mold with a mold spacing of 4mm, an insulation thickness of 0.9-1.1mm, and a concentricity of ≥80%. After extrusion vulcanization, the insulation adhesion is 40-60N. The semi-extrusion mold can be flexibly adjusted and customized according to the shape and size of the cable insulation layer, and is suitable for the production of cable insulation layers of different models, specifications and requirements. By replacing different parts of the mold, cable insulation layers of various shapes and sizes can be manufactured.

[0030] According to the automotive industry ISO 19642 standard, the sample cable was tested for softness, and the results are as follows:

[0031] Table 1 Softness test

[0032]

[0033] 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. An ultra-soft low-voltage aluminum conductor cable for new energy vehicles, comprising a conductor and an insulating layer arranged in sequence from the inside to the outside; characterized in that: The conductor is formed by 12 strands of wires twisted in a 3+9 layered form by a cage stranding machine with 100% complete back-twisting. Specifically, the conductor includes 3 inner strands and 9 outer strands uniformly arranged on the outer periphery of the inner strands; wherein the twisting pitch-diameter ratio of the 3 inner strands is 22 to 25 times and is left-twisted, and the twisting pitch-diameter ratio of the 9 outer strands is 15 to 17 times and is left-twisted; All strands are composed of an equal number of aluminum monofilaments in a bundle twisted manner, and the twisting direction is left-handed; specifically, each inner and outer layer strand includes 5 inner layer aluminum monofilaments and 11 outer layer aluminum monofilaments evenly arranged on the periphery of the inner layer aluminum monofilaments; each of the strands has a pitch-diameter ratio of 25 to 30 times and is left-twisted; The insulating layer is wrapped around the outside of the conductor.

2. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The grade of the aluminum monofilament is AW-1370.

3. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The conductor cross section is 40 mm 2 .

4. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 3, characterized in that: The diameter of the aluminum monofilament ranges from 0.49 mm to 0.50 mm.

5. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The twisting pitch of each strand is 55-65 mm.

6. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The twisting pitch of the three inner strands is 100-110mm.

7. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The twisting pitch of the 9 outer strands is 120-130mm.

8. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The insulating layer is a silicone rubber layer, and the silicone rubber material has a hardness of 63±2 degrees.

9. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The tensile strength of the aluminum monofilament bundle is 80 to 100 MPa.

10. The ultra-soft low-voltage aluminum conductor cable for new energy vehicles according to claim 1, characterized in that: The elongation of the aluminum filament bundle is 20% to 30%.

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