Copper core silicone rubber insulated road vehicle in-vehicle cable

Abstract

The utility model relates to the technical field of electric vehicle cables, and specifically to a copper core silicone rubber insulated in-vehicle cable for road vehicles, comprising: a conductor, wherein the conductor is a copper wire twisted structure; an inner shielding layer, coated on the outer wall of the conductor; an inner insulating layer extruded on the outer wall of the inner shielding layer; a braided shielding layer, coated on the outer wall of the inner insulating layer; an aluminum foil shielding layer, wrapped around the outer wall of the braided shielding layer; and an outer insulating layer, extruded on the outer wall of the aluminum foil shielding layer. The conductor of the present application adopts a fine copper wire twisted structure, which makes the conductor softer and less stressed under bending and vibration. An aluminum tape shielding layer is arranged outside the conductor to increase the anti-interference and shielding effect of the conductor, and can protect the inner layer of the insulation to avoid being punctured by the conductor. Through the arrangement of double-layer silicone rubber insulation, the cable has good pressure resistance, temperature resistance and bending performance, which can ensure the reliability and service life of the cable.

Description

Technical Field

[0001] The utility model relates to the technical field of electric vehicle cables, in particular to a copper core silicone rubber insulated in-vehicle cable for road vehicles. Background Art

[0002] The main function of high-voltage cables for electric vehicles is to distribute the internal wiring harness of the power distribution system, transmit electric energy efficiently and with high quality, and shield external signal interference. High-voltage cables are the neural network of the high-voltage system of new energy vehicles, which is crucial to ensure the normal operation of the vehicle and the safety of passengers. The structure of high-voltage cables for electric vehicles usually includes conductor layer, insulation layer, shielding layer, sheath layer and other parts. The conductor layer is responsible for transmitting electric energy, the insulation layer ensures the safety of electric energy transmission, the shielding layer is used to reduce electromagnetic interference, and the sheath layer protects the cable from external damage.

[0003] The conductor material of the in-vehicle cable is generally the national standard Category 6 soft conductor to ensure the softness and toughness of the copper monofilament. However, due to the small diameter of the monofilament of Category 6 conductor, the outer monofilament may break due to vibration or extrusion or bending stress during normal operation of the vehicle, which will have an adverse effect on the inner insulation. Utility Model Content

[0004] In view of the technical problems existing in the prior art of high-voltage cables in electric vehicles, the first aspect of the utility model proposes a copper core silicone rubber insulated road vehicle in-vehicle cable, comprising:

[0005] Conductor, the conductor is a copper wire twisted structure;

[0006] An inner shielding layer, covering the outer wall of the conductor;

[0007] The inner insulating layer is extruded on the outer wall of the inner shielding layer;

[0008] A braided shielding layer, covering the outer wall of the inner insulating layer;

[0009] An aluminum foil shielding layer wrapped around the outer wall of the braided shielding layer;

[0010] An outer insulating layer, extruded on the outer wall of the aluminum foil shielding layer;

[0011] Wherein, the inner shielding layer comprises a composite wrapping layer of a semi-conductive tape and an aluminum tape.

[0012] Preferably, the inner shielding layer comprises a first semi-conductive wrapping layer, an aluminum tape wrapping layer and a second semi-conductive wrapping layer which are distributed from the inside to the outside.

[0013] Preferably, the first semi-conductive wrapping layer comprises a first polyester tape wrapping structure with a wrapping overlap rate of 40-50%, the aluminum tape wrapping layer comprises an aluminum tape wrapping structure with a wrapping overlap rate of less than 10%, and the second semi-conductive wrapping layer comprises a second polyester tape wrapping structure with a wrapping overlap rate of less than 10%.

[0014] Preferably, the thickness of the aluminum tape in the aluminum tape wrapping layer is 0.20-0.22 mm.

[0015] Preferably, the inner insulating layer and the outer insulating layer comprise silicone rubber insulating layers.

[0016] Preferably, the thickness of the outer insulating layer is 1.2 times the thickness of the inner insulating layer.

[0017] Preferably, the braided shielding layer adopts a tinned copper wire braiding structure with a braiding density of not less than 85%, and the aluminum foil shielding layer adopts an aluminum foil left-handed wrapping structure with a wrapping overlap rate of not less than 10%.

[0018] Preferably, the conductor includes a central wire bundle, a first wire bundle twisted layer, a second wire bundle twisted layer and a third wire bundle twisted layer, the central wire bundle includes a bundle of fine copper wire bundles, the first wire bundle twisted layer includes 6 bundles of fine copper wire bundles, the second wire bundle twisted layer includes 12 bundles of fine copper wire bundles, and the third wire bundle twisted layer includes 18 bundles of fine copper wire bundles.

[0019] Preferably, the central wire bundle, the first wire bundle twisted layer, the second wire bundle twisted layer and the third wire bundle twisted layer all adopt a left-handed multiple-twisted structure, and each bundle of fine copper wires adopts a left-handed bundle twisted structure.

[0020] Preferably, the re-twisting pitches of the first strand twisted layer, the second strand twisted layer and the third strand twisted layer gradually increase.

[0021] Compared with the prior art, the copper core silicone rubber insulated road vehicle in-vehicle cable conductor of the utility model adopts a fine copper wire twisted structure, which makes the conductor softer and less stressed under bending and vibration. An aluminum tape shielding layer is arranged outside the conductor to increase the anti-interference and shielding effect of the conductor and protect the inner layer of the insulation to avoid being punctured by the conductor. Through the setting of double-layer silicone rubber insulation, the cable has good pressure resistance, temperature resistance and bending performance, which can ensure the reliability and service life of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings are not intended to be drawn to scale. In the accompanying drawings, each identical or approximately identical component shown in each figure may be represented by the same reference numeral. For clarity, not every component is labeled in each figure. Now, embodiments of various aspects of the utility model will be described by way of example and with reference to the accompanying drawings.

[0023] Figure 1The utility model is a schematic structural diagram of a copper core silicone rubber insulated road vehicle in-vehicle cable.

[0024] Figure 2 The utility model is a schematic diagram of the cross-sectional structure of a copper core silicone rubber insulated road vehicle in-vehicle cable.

[0025] Figure 3 It is a structural schematic diagram of the inner shielding layer shown in the utility model.

[0026] Figure 4 It is a transfer impedance test data diagram shown in an embodiment of the present utility model.

[0027] Figure 5 It is a shielding attenuation test data diagram shown in an embodiment of the present utility model. DETAILED DESCRIPTION

[0028] In order to better understand the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.

[0029] Combination Figure 1 to Figure 3 The copper core silicone rubber insulated road vehicle automobile cable of the illustrated embodiment comprises a conductor 1 , an inner shielding layer 2 , an inner insulating layer 3 , a braided shielding layer 4 , an aluminum foil shielding layer 5 and an outer insulating layer 6 .

[0030] Combination Figure 1 , 2 The inner shielding layer 2 is wrapped around the outer wall of the conductor 1, the inner insulating layer 3 is extruded around the outer wall of the inner shielding layer 2, the braided shielding layer 4 is wrapped around the outer wall of the inner insulating layer 3, the aluminum foil shielding layer 5 is wrapped around the outer wall of the braided shielding layer 4, and the outer insulating layer 6 is extruded around the outer wall of the aluminum foil shielding layer 5.

[0031] In order to ensure the flexibility of the conductor 1, the conductor 1 is a copper wire twisted structure.

[0032] Optionally, the conductor 1 includes a central wire bundle 11, a first wire bundle twisted layer 12, a second wire bundle twisted layer 13 and a third wire bundle twisted layer 14, the central wire bundle 11 includes a bundle of fine copper wire bundles, the first wire bundle twisted layer 12 includes 6 bundles of fine copper wire bundles, the second wire bundle twisted layer 13 includes 12 bundles of fine copper wire bundles, and the third wire bundle twisted layer 14 includes 18 bundles of fine copper wire bundles.

[0033] Thus, the conductor 1 includes 37 copper wire bundles in total, with 64 thin copper wires per strand in the central wire bundle 11, the first wire bundle twisted layer 12 and the third wire bundle twisted layer 14, and 63 thin copper wires per strand in the second wire bundle twisted layer 13. By reducing the number of copper wires in the second wire bundle twisted layer 13, the space for the third wire bundle twisted layer 14 to deform inwards can be increased, thereby reducing the bending stress of the conductor.

[0034] Optionally, the single wire diameter of the thin copper wire is 0.195 mm.

[0035] Furthermore, in order to ensure the tightness of the conductor, the central wire bundle 11, the first wire bundle twisted layer 12, the second wire bundle twisted layer 13 and the third wire bundle twisted layer 14 all adopt a left-handed multiple-twisted structure, and each bundle of fine copper wires adopts a left-handed bundle twisted structure.

[0036] Preferably, the twisted pitches of the first strand twisted layer 12, the second strand twisted layer 13 and the third strand twisted layer 14 gradually increase.

[0037] In an optional embodiment, each strand of wire is twisted in a left-hand direction with a twisting pitch of 40 to 45.

[0038] The first strand twisted layer 12 is left-hand twisted with a twist pitch of 90-100, the second strand twisted layer 13 is left-hand twisted with a twist pitch of 130-146, and the third strand twisted layer 14 is left-hand twisted with a twist pitch of 132-154.

[0039] In the above conductor stranding process, bare copper wire is used as the conductor. In the process of wire bundling and re-twisting, the tension of the pay-off reel is controlled, and the wire is fully paid off on the reel to reduce wire breakage and wire replacement. The various wire cores after wire bundling and the stranded wires for re-twisting are not allowed to be twisted and welded as a whole; re-twisting should be produced on a cage stranding machine, and the stranded wire cores are round and not loose.

[0040] Furthermore, the inner shielding layer 2 comprises a composite wrapping layer of a semi-conductive tape and an aluminum tape. Thus, the aluminum tape wrapping structure can reduce the probability of the thin copper wire in the conductor piercing the inner surface of the insulation, thereby protecting the inner surface of the insulation layer.

[0041] like Figure 3 As shown, the inner shielding layer 2 includes a first semiconductive wrapping layer 21, an aluminum tape wrapping layer 22 and a second semiconductive wrapping layer 23 which are arranged from the inside to the outside.

[0042] Among them, the first semi-conductive wrapping layer 21 includes a first polyester tape wrapping structure with a wrapping overlap rate of 40-50%, the aluminum tape wrapping layer 22 includes an aluminum tape wrapping structure with a wrapping overlap rate of less than 10%, and the second semi-conductive wrapping layer 23 includes a second polyester tape wrapping structure with a wrapping overlap rate of less than 10%.

[0043] In an optional embodiment, the first polyester tape has a thickness of 0.1 mm and a width of 20-40 mm, the thickness of the aluminum tape in the aluminum tape wrapping layer 22 is 0.20-0.22 mm, and the thickness of the second polyester tape is 0.05 mm.

[0044] In this way, a semiconductive layer is formed on the surface of the conductor through the three-layer structure of the first polyester tape-aluminum tape-second polyester tape, and a gradient electric field and a uniform surface are formed, so that the electric field distribution on the insulating surface is uniform, and the conductor is prevented from puncturing and damaging the inner wall of the insulation.

[0045] In an optional embodiment, the inner insulating layer 3 and the outer insulating layer 6 include silicone rubber insulating layers. The silicone rubber layer has good flexibility and high temperature resistance to meet the use requirements.

[0046] Preferably, the thickness of the outer insulating layer 6 is 1.2 times the thickness of the inner insulating layer 3 .

[0047] Optionally, the thickness of the outer insulating layer 6 is 1.2 mm, and the thickness of the inner insulating layer 3 is 1.0 mm.

[0048] Furthermore, the braided shielding layer 4 adopts a tinned copper wire braiding structure with a braiding density of not less than 85%, and the aluminum foil shielding layer 5 adopts an aluminum foil left-handed wrapping structure with a wrapping overlap rate of not less than 10%.

[0049] In this way, good anti-interference and shielding effects are formed by the inner shielding layer and the shielding layer between the inner and outer insulating layers.

[0050] The results of the performance test of this application are shown in Table 1:

[0051]

[0052]

[0053] In combination with the above embodiments, in the design of the copper core silicone rubber insulated road vehicle in-vehicle cable of the utility model, the conductor adopts a fine copper wire twisted structure, which makes the conductor softer and less stressed under bending and vibration. An aluminum tape shielding layer is arranged outside the conductor to increase the anti-interference and shielding effect of the conductor, and can protect the inner layer of the insulation to avoid being punctured by the conductor. Through the setting of double-layer silicone rubber insulation, the cable has good pressure resistance, temperature resistance and bending performance, which can ensure the reliability and service life of the cable.

[0054] Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. A person with ordinary knowledge in the technical field to which the present invention belongs may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be determined by the definition of the claims.

Claims

1. A copper core silicone rubber insulated road vehicle in-vehicle cable, characterized in that: include: A conductor (1), wherein the conductor (1) is a copper wire twisted structure; An inner shielding layer (2) covering the outer wall of the conductor (1); The inner insulating layer (3) is extruded onto the outer wall of the inner shielding layer (2); A braided shielding layer (4) wrapped around the outer wall of the inner insulating layer (3); An aluminum foil shielding layer (5) wrapped around the outer wall of the braided shielding layer (4); An outer insulating layer (6) is extruded onto the outer wall of the aluminum foil shielding layer (5); Wherein, the inner shielding layer (2) comprises a composite wrapping layer of a semi-conductive tape and an aluminum tape.

2. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 1, characterized in that: The inner shielding layer (2) comprises a first semi-conductive wrapping layer (21), an aluminum tape wrapping layer (22), and a second semi-conductive wrapping layer (23) which are arranged from the inside to the outside.

3. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 2, characterized in that: The first semi-conductive wrapping layer (21) comprises a first polyester tape wrapping structure, with a wrapping overlap rate of 40-50%, the aluminum tape wrapping layer (22) comprises an aluminum tape wrapping structure, with a wrapping overlap rate of less than 10%, and the second semi-conductive wrapping layer (23) comprises a second polyester tape wrapping structure, with a wrapping overlap rate of less than 10%.

4. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 3, characterized in that: The thickness of the aluminum tape in the aluminum tape wrapping layer (22) is 0.20-0.22 mm.

5. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 1, characterized in that: The inner insulating layer (3) and the outer insulating layer (6) comprise silicone rubber insulating layers.

6. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 1, characterized in that: The thickness of the outer insulating layer (6) is 1.2 times the thickness of the inner insulating layer (3).

7. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 1, characterized in that: The braided shielding layer (4) adopts a tinned copper wire braiding structure with a braiding density of not less than 85%, and the aluminum foil shielding layer (5) adopts an aluminum foil left-handed wrapping structure with a wrapping overlap rate of not less than 10%.

8. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 1, characterized in that: The conductor (1) comprises a central wire bundle (11), a first wire bundle twisted layer (12), a second wire bundle twisted layer (13) and a third wire bundle twisted layer (14), wherein the central wire bundle (11) comprises a bundle of fine copper wire bundles, the first wire bundle twisted layer (12) comprises 6 bundles of fine copper wire bundles, the second wire bundle twisted layer (13) comprises 12 bundles of fine copper wire bundles, and the third wire bundle twisted layer (14) comprises 18 bundles of fine copper wire bundles.

9. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 8, characterized in that: The central wire bundle (11), the first wire bundle twisted layer (12), the second wire bundle twisted layer (13) and the third wire bundle twisted layer (14) all adopt a left-handed multiple twisted structure, and each bundle of fine copper wires adopts a left-handed bundle twisted structure.

10. The copper core silicone rubber insulated road vehicle in-vehicle cable according to claim 8, characterized in that: The re-twisting pitches of the first filament bundle twisted layer (12), the second filament bundle twisted layer (13) and the third filament bundle twisted layer (14) gradually increase.

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