A high-performance, lightweight high-voltage cable for new energy vehicles

Abstract

The utility model relates to the technical field of automotive cables, and in particular to a high-performance, lightweight high-voltage cable for new energy vehicles. It includes an aluminum alloy conductor layer arranged at the axis of the entire conductor and a copper conductor layer attached to the outside thereof, the aluminum alloy conductor layer and the copper conductor layer are coaxially arranged; the outside of the copper conductor layer is coated with non-woven fabric; the aluminum alloy conductor layer is divided into three layers from the inside to the outside, and the three aluminum alloy conductor layers and the outer copper conductor layer are twisted in a regular manner; the first layer of aluminum alloy conductor located at the axis is twisted by fiber filaments and aluminum alloy monofilaments; the second layer of aluminum alloy conductor is twisted by multiple groups of fan-shaped aluminum alloy strands around the outside of the first layer of aluminum alloy conductor; the third layer of aluminum alloy conductor is twisted by multiple groups of fan-shaped aluminum alloy strands around the outside of the second layer of aluminum alloy conductor; the copper conductor layer is twisted by multiple groups of cylindrical copper strands. The cable combines the advantages of aluminum alloy and copper, and has light weight, high conductivity, good corrosion resistance and high temperature resistance.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile cables, in particular to a high-performance and lightweight high-voltage cable for new energy vehicles. Background Art

[0002] With the development of the new energy vehicle industry, the performance requirements for high-voltage connecting cables inside automobiles are increasing, especially in terms of conductivity, mechanical strength, heat resistance and lightweight. Although traditional pure copper conductors have good conductivity, they are heavy and are not conducive to the lightweight design of the entire vehicle. Conductor materials are an important component of key components such as batteries and motors. Although traditional copper stranded wires have good conductivity, they may not meet the requirements of new energy vehicles for material weight, corrosion resistance and high temperature resistance in some cases. Therefore, in order to meet the development needs of new energy vehicles, it is necessary to develop a new type of stranded wire conductor material that can not only meet the requirements of high conductivity and mechanical strength, but also effectively reduce weight. Utility Model Content

[0003] In view of the defects of the prior art, the utility model proposes a high-performance lightweight high-voltage cable for new energy vehicles. The cable combines the advantages of aluminum alloy and copper, and has the characteristics of light weight, high conductivity, good corrosion resistance and high temperature resistance.

[0004] The utility model is achieved in this way:

[0005] A high-performance lightweight high-voltage cable for new energy vehicles, comprising an aluminum alloy conductor layer arranged at the entire conductor axis and a copper conductor layer attached to the outside thereof, wherein the aluminum alloy conductor layer and the copper conductor layer are coaxially arranged; the outside of the copper conductor layer is coated with non-woven fabric; the aluminum alloy conductor layer is divided into three layers from the inside to the outside, and the three aluminum alloy conductor layers and the outer copper conductor layer are twisted in a regular manner;

[0006] The first layer of aluminum alloy conductor located at the axis is formed by twisting fiber filaments and aluminum alloy monofilaments; the second layer of aluminum alloy conductor is formed by twisting multiple groups of fan-shaped aluminum alloy strands wrapped around the outside of the first layer of aluminum alloy conductor; the third layer of aluminum alloy conductor is formed by twisting multiple groups of fan-shaped aluminum alloy strands wrapped around the outside of the second layer of aluminum alloy conductor; the copper conductor layer is formed by twisting multiple groups of cylindrical copper strands.

[0007] Furthermore, the three aluminum alloy conductor layers and the outer copper conductor layers are twisted in a regular 1+6+12+18 pattern.

[0008] Furthermore, the pitch-diameter ratio of the first layer of aluminum alloy conductors is 18-20 times; the pitch-diameter ratio of the second layer of aluminum alloy conductors is 13-16 times; and the pitch-diameter ratio of the third layer of aluminum alloy conductors is 11-13 times.

[0009] Furthermore, the ratio of the number of fiber filaments to the number of aluminum alloy monofilaments in the first layer of aluminum alloy conductor is 3:1.

[0010] Furthermore, the fiber filaments have a density of 1000-3600 dtex.

[0011] Furthermore, each group of sector-shaped aluminum alloy strands of the second layer of aluminum alloy conductors is formed by twisting 30-50 aluminum alloy monofilaments at a twisting pitch diameter ratio of 15-18 times.

[0012] Furthermore, each group of sector-shaped aluminum alloy strands of the third layer of aluminum alloy conductors is formed by twisting 30-50 aluminum alloy monofilaments at a twisting pitch diameter ratio of 15-18 times.

[0013] Furthermore, the copper strands of the copper conductor layer have a twisted pitch diameter ratio of 8-10 times.

[0014] Furthermore, each group of copper strands of the copper conductor layer is formed by twisting 15-25 copper monofilaments at a twisting pitch diameter ratio of 15-18 times.

[0015] Furthermore, the diameters of the aluminum alloy monofilaments in the three aluminum alloy conductor layers are equal, and the diameter ratio of the aluminum alloy monofilaments to the copper monofilaments is 2:1.

[0016] The utility model has the following advantages and technical effects:

[0017] The new energy vehicle high-voltage cable made by the utility model combines the advantages of light weight of aluminum alloy and good electrical properties of copper. Compared with traditional single copper cables, it ensures the lightweight of the cable while taking into account the electrical performance of the product. It has light weight, high conductivity and stable structure, which helps to improve the overall energy efficiency of electric vehicles, increase the life of cables and reduce production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic cross-sectional view of the high voltage cable of the utility model.

[0019] In the figure: 1. The first layer of aluminum alloy conductor; 2. The second layer of aluminum alloy conductor; 3. The third layer of aluminum alloy conductor; 4. Copper conductor layer; 5. Non-woven fabric. DETAILED DESCRIPTION

[0020] 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.

[0021] like Figure 1As shown, the utility model discloses a high-performance lightweight high-voltage cable for new energy vehicles, including an aluminum alloy conductor layer arranged at the entire conductor axis and a copper conductor layer 4 tightly attached to the outside thereof, the aluminum alloy conductor layer and the copper conductor layer 4 are coaxially arranged; the outside of the copper conductor layer 4 is coated with a non-woven fabric 5 with a thickness of 0.02-0.5 mm.

[0022] The aluminum alloy conductor layer is divided into three layers from the inside to the outside, and the three aluminum alloy conductor layers and the outer copper conductor layer thereof are twisted in a regular manner of 1+6+12+18.

[0023] The first layer of aluminum alloy conductor 1 located at the axis is formed by twisting fiber filaments and aluminum alloy monofilaments, with a twisting pitch diameter ratio of 18-20 times; the fiber filament and aluminum alloy monofilament root number ratio is 3:1, the fiber filament density is 1000-3600dtex, the aluminum alloy monofilament diameter is 0.3-0.52mm, and the fiber filament root number is 7-10.

[0024] The second layer of aluminum alloy conductor 2 is formed by twisting 6 groups of fan-shaped aluminum alloy strands around the outside of the first layer of aluminum alloy conductor 1, with a twisting pitch-diameter ratio of 13-16 times; each group of fan-shaped aluminum alloy strands is formed by twisting 30-50 aluminum alloy single wires with a diameter of 0.3-0.52mm at a twisting pitch-diameter ratio of 15-18 times.

[0025] The third layer of aluminum alloy conductor 3 is formed by twisting 12 groups of fan-shaped aluminum alloy strands around the outside of the second layer of aluminum alloy conductor 2, with a twisting pitch-diameter ratio of 11-13 times; each group of fan-shaped aluminum alloy strands is formed by twisting 30-50 aluminum alloy single wires with a diameter of 0.3-0.52mm at a twisting pitch-diameter ratio of 15-18 times.

[0026] The copper conductor layer 4 is formed by twisting 18 groups of cylindrical copper strands, with a twisting pitch-diameter ratio of 8-10 times; each group of copper strands is formed by twisting 15-25 copper monofilaments with a diameter of 0.15-0.25 mm according to a twisting pitch-diameter ratio of 15-18 times;

[0027] The ratio of the diameter of the aluminum alloy single wire to the diameter of the copper single wire is 2: 1. Thus, the aluminum alloy wires and the copper wires and the copper wires and the aluminum alloy wires can be well combined without too much gap, thereby ensuring the electrical performance and mechanical strength and reducing the volume of the entire conductor.

[0028] The new energy vehicle high-voltage cable made of the aluminum alloy copper stranded wire conductor of the utility model achieves lightweight conductors while ensuring electrical performance, helps to improve the overall energy efficiency of electric vehicles, and reduces production costs.

[0029] 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-performance, lightweight high-voltage cable for new energy vehicles, characterized in that: It includes an aluminum alloy conductor layer arranged at the axis of the entire conductor and a copper conductor layer attached to the outside thereof, the aluminum alloy conductor layer and the copper conductor layer are coaxially arranged; the outside of the copper conductor layer is covered with non-woven fabric; the aluminum alloy conductor layer is divided into three layers from the inside to the outside, and the three aluminum alloy conductor layers and the outer copper conductor layer are twisted in a regular manner; The first layer of aluminum alloy conductor located at the axis is formed by twisting fiber filaments and aluminum alloy monofilaments; the second layer of aluminum alloy conductor is formed by twisting multiple groups of fan-shaped aluminum alloy strands wrapped around the outside of the first layer of aluminum alloy conductor; the third layer of aluminum alloy conductor is formed by twisting multiple groups of fan-shaped aluminum alloy strands wrapped around the outside of the second layer of aluminum alloy conductor; the copper conductor layer is formed by twisting multiple groups of cylindrical copper strands.

2. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The three-layer aluminum alloy conductor layer and the outer copper conductor layer are twisted in a regular 1+6+12+18 pattern.

3. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The first layer of aluminum alloy conductors has a twisted pitch-diameter ratio of 18-20 times; the second layer of aluminum alloy conductors has a twisted pitch-diameter ratio of 13-16 times; and the third layer of aluminum alloy conductors has a twisted pitch-diameter ratio of 11-13 times.

4. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The ratio of the number of fiber filaments to the number of aluminum alloy monofilaments in the first layer of aluminum alloy conductor is 3:

1.

5. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The fiber filaments have a density of 1000-3600 dtex.

6. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: Each group of sector-shaped aluminum alloy strands of the second layer of aluminum alloy conductors is formed by twisting 30 to 50 aluminum alloy monofilaments at a twisting pitch diameter ratio of 15 to 18 times.

7. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: Each group of sector-shaped aluminum alloy strands of the third layer of aluminum alloy conductors is formed by twisting 30 to 50 aluminum alloy monofilaments at a twisting pitch diameter ratio of 15 to 18 times.

8. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The copper strands of the copper conductor layer have a twisted pitch diameter ratio of 8-10 times.

9. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: Each group of copper strands in the copper conductor layer is formed by twisting 15 to 25 copper monofilaments at a twisting pitch ratio of 15 to 18 times.

10. The high-performance, lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The aluminum alloy single wires in the three aluminum alloy conductor layers have the same diameter, and the diameter ratio of the aluminum alloy single wire to the copper single wire is 2:1.

Images