Aluminum alloy cable

Abstract

The utility model belongs to the technical field of cable manufacturing, and discloses an aluminum alloy cable, which comprises a conductor, an insulating layer, a shielding layer and a sheath layer, and is characterized in that the conductor comprises a plurality of aluminum alloy guide cores and a plurality of connecting terminals, the connecting terminals are flexible conductive pieces, and the insulating layer is arranged between the conductor and the insulating layer. The plurality of aluminum alloy conductor cores are connected through the plurality of connecting terminals to form a conductor, the insulating layer wraps the periphery of the conductor, so that the aluminum alloy cable has insulating performance, the shielding layer wraps the periphery of the insulating layer, the aluminum alloy cable is prevented from being interfered by external electromagnetic interference, the sheath layer wraps the periphery of the shielding layer, and the sheath layer wraps the periphery of the shielding layer. Therefore, the friction resistance and the extrusion resistance of the aluminum alloy cable are improved. The aluminum alloy cable is simple in processing procedure and high in flexibility, the shape of the aluminum alloy cable can be adjusted at will, workers can conduct wiring on an automobile conveniently, and cable manufacturers can conduct production conveniently.

Description

Technical Field

[0001] The utility model relates to the technical field of cable manufacturing, in particular to an aluminum alloy cable. Background Art

[0002] With the development of the new energy field, new energy vehicles have gradually become popular and have become one of people's travel methods. Most of the electrical components inside new energy vehicles are connected by cables. Most of the existing cables use copper as a conductor. Since copper is relatively heavy and expensive, the cables used in new energy vehicles are heavy and expensive, resulting in high manufacturing costs for new energy vehicles. In addition, the vehicles themselves have a large weight, which causes fast power consumption during driving, affecting the overall endurance of new energy vehicles.

[0003] Therefore, cables with solid aluminum alloy as conductors have appeared on the market, which have reduced the price of cables while reducing their weight. However, cables with solid aluminum alloy as conductors on the market need to be bent by a bending machine to adjust their overall shape. When workers are wiring new energy vehicles, the shape of cables with solid aluminum alloy as conductors is difficult to adjust and has poor flexibility. They need to be bent by a bending machine. At the same time, a new energy vehicle will use multiple cables of different shapes, which is not convenient for cable manufacturers to produce.

[0004] Therefore, there is an urgent need for an aluminum alloy cable to solve the above technical problems. Utility Model Content

[0005] The utility model aims to provide an aluminum alloy cable to solve the problem that the existing cables have poor flexibility in use, need to be bent by a bending machine, and are inconvenient for cable manufacturers to produce.

[0006] To achieve this purpose, the utility model adopts the following technical solutions:

[0007] An aluminum alloy cable, comprising:

[0008] Conductor, the conductor comprises an aluminum alloy conductor core and a connecting terminal, the connecting terminal is a flexible conductive member, a plurality of the aluminum alloy conductor cores are provided; a plurality of the connecting terminals are provided, and the plurality of connecting terminals are used to form a connection between the plurality of the aluminum alloy conductor cores;

[0009] An insulating layer, covering the outer periphery of the conductor;

[0010] A shielding layer, covering the outer periphery of the insulating layer;

[0011] The sheath layer is coated on the outer periphery of the shielding layer.

[0012] As a preferred technical solution for aluminum alloy cables, the insulating layer is made of ceramicized irradiated self-crosslinking polyolefin.

[0013] As a preferred technical solution for the aluminum alloy cable, the shielding layer is formed by winding an aluminum foil tape around the outer periphery of the insulating layer;

[0014] Alternatively, the shielding layer is formed by winding a copper tape around the outer circumference of the insulating layer.

[0015] As a preferred technical solution for the aluminum alloy cable, the connecting terminal has welding areas at both ends along the length direction, and the aluminum alloy conductor has protrusions at both ends along the length direction, and the welding areas and the protrusions are welded to each other.

[0016] As an optimal technical solution for aluminum alloy cables, the connecting terminal is formed by extruding multiple layers of copper strips, and both ends of the multiple layers of copper strips along the length direction are connected by welding, and the two ends of the multiple layers of copper strips are welded as the welding area.

[0017] As a preferred technical solution for aluminum alloy cables, the welding method is ultrasonic welding.

[0018] As a preferred technical solution of the aluminum alloy cable, the aluminum alloy cable further includes a filler, and the filler is filled in the gap between the shielding layer and the sheath layer.

[0019] As a preferred technical solution for aluminum alloy cables, the filler can be selected from one of polypropylene rope, glass fiber rope, asbestos rope or rubber.

[0020] As a preferred technical solution for aluminum alloy cables, the sheath layer is made of radiation cross-linked low-smoke halogen-free flame-retardant polyolefin material.

[0021] As a preferred technical solution of the aluminum alloy cable, the aluminum alloy cable further includes a hydrophilic coating, and the hydrophilic coating is coated on the outer periphery of the sheath layer.

[0022] The beneficial effects of the utility model are:

[0023] The aluminum alloy cable provided by the utility model uses a flexible conductive part as a connecting terminal, and uses the connecting terminal to connect multiple aluminum alloy conductors to make a conductor. The aluminum alloy conductor can be formed by turning the aluminum alloy material and then cutting it with a cutting device. The processing procedure is simple and can be processed quickly. Compared with the technical solution of the prior art that uses a solid aluminum alloy as a conductor and uses a connecting terminal to connect the aluminum alloy conductors to form a conductor, the overall flexibility of the conductor after assembly is high. When wiring, the shape of the aluminum alloy cable can be adjusted at will to achieve fast and flexible wiring. It solves the technical problem that the cable in the prior art that uses a solid aluminum alloy as a conductor needs to be bent using a bending machine, and that it is necessary to produce a variety of cables of different shapes according to the wiring conditions of the car, which makes it difficult for cable manufacturers to process.

[0024] The preparation method of the aluminum alloy cable provided by the utility model has simple processing steps, and the processed aluminum alloy cable has high flexibility and the shape can be adjusted at will, which is convenient for workers to wire the car and convenient for cable manufacturers to produce. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a structural schematic diagram of the aluminum alloy cable provided by the utility model;

[0026] Figure 2 It is a schematic diagram of the aluminum alloy core structure of the aluminum alloy cable provided by the utility model;

[0027] Figure 3 The utility model provides a flow chart of the method for preparing the aluminum alloy cable.

[0028] In the figure:

[0029] 1. Conductor; 11. Aluminum alloy core; 111. Protrusion; 2. Insulation layer; 3. Shielding layer; 4. Sheath layer; 5. Filler. DETAILED DESCRIPTION

[0030] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only the parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0031] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0032] In the present utility model, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0033] In the description of this embodiment, the terms "upper", "lower", "right", etc., are based on the directions or positions shown in the drawings, and are only for the convenience of description and simplified operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0034] like Figure 1 to Figure 2 As shown in , this embodiment provides an aluminum alloy cable, including a conductor 1, an insulating layer 2, a shielding layer 3 and a sheath layer 4, wherein the conductor 1 includes an aluminum alloy conductor 11 and a connecting terminal, the connecting terminal is a flexible conductive part, and the aluminum alloy conductor 11 and the connecting terminal are both provided with a plurality of them, and the plurality of connecting terminals connect the plurality of aluminum alloy conductors 11 to form a conductor 1. Furthermore, the insulating layer 2 is coated on the periphery of the conductor 1, so that the aluminum alloy cable has insulating properties and prevents the aluminum alloy cable from leaking electricity during use. The shielding layer 3 is coated on the periphery of the insulating layer 2 to prevent the aluminum alloy cable from being interfered by external electromagnetic interference and ensure the stability of current conduction when the aluminum alloy cable transmits current. The sheath layer 4 is coated on the periphery of the shielding layer 3 to improve the friction resistance and extrusion resistance of the aluminum alloy cable and to increase the service life of the aluminum alloy cable.

[0035] The aluminum alloy cable provided in this embodiment uses a flexible conductive part as a connecting terminal, and uses the connecting terminal to connect multiple aluminum alloy cores 11 to make a conductor 1. The aluminum alloy core 11 can be formed by turning the aluminum alloy material and then cutting it with a cutting device. The processing procedure is simple and can be processed quickly. Compared with the technical solution of the prior art that uses a solid aluminum alloy as the conductor 1, the connecting terminal is used to connect the aluminum alloy cores 11 to form the conductor 1. The overall flexibility of the conductor 1 after assembly is high. When wiring, the shape of the aluminum alloy cable can be adjusted at will to achieve fast and flexible wiring. It solves the technical problem that the cable with a solid aluminum alloy as the conductor 1 in the prior art needs to be bent by a bending machine, and a variety of cables with different shapes need to be produced according to the wiring conditions of the car, which makes it difficult for cable manufacturers to process.

[0036] As preferably, the material of the insulating layer 2 is a ceramic irradiated self-crosslinked polyolefin material. By adding a ceramic material to the irradiated self-crosslinked polyolefin material, on the one hand, if the insulating layer 2 burns, the ceramic material will form a carbon layer during the combustion process, and the carbon layer can block the flame from burning the internal structure of the insulating layer 2, playing a fire-resistant role. At the same time, the formation of the carbon layer can also prevent the insulating layer 2 from dripping flames when burning, avoiding the peripheral diffusion of the flame. In this way, the addition of the ceramic material can achieve a fire-resistant effect without adding a fire-resistant layer to the aluminum alloy, and can further improve the safety of use of the aluminum alloy cable, and will not increase the diameter of the aluminum alloy cable, further ensuring the lightweight of the aluminum alloy cable. On the other hand, the addition of the irradiated self-crosslinked polyolefin material enables the insulating layer 2 to produce an irradiation reaction after being placed for a period of time, and does not need to be irradiated. The strength of the insulating layer 2 can also be kept consistent, with good anti-extrusion performance, and the processing procedures of the aluminum alloy cable are reduced, and the difficulty of the work of the staff is reduced. It is worth noting that the insulating layer 2 is made of ceramicized irradiated self-crosslinked polyolefin material, which is only a preferred option for the selection of the insulating layer 2. The insulating layer 2 can also be made of plastic material, rubber material or polyvinyl fluoride material.

[0037] Preferably, the shielding layer 3 is formed by winding an aluminum foil tape around the outer periphery of the insulating layer 2, so that the aluminum foil tape can be flatly attached to the outer periphery of the insulating layer 2, further reducing the diameter of the aluminum alloy cable and ensuring the roundness of the aluminum alloy cable. At the same time, the aluminum foil tape is wrapped around the outer periphery of the insulating layer 2 in a spiral winding manner, which can achieve full coverage of the outer periphery of the insulating layer 2 and further enhance the shielding effect of the aluminum alloy cable. Of course, the shielding layer 3 can also be formed by winding a copper tape around the outer periphery of the insulating layer 2. Of course, the shielding layer 3 can also be formed by braiding copper wires, and no specific restrictions are made here on the processing scheme of the shielding layer 3.

[0038] Regarding the connection between the connecting terminal and the aluminum alloy conductor core 11, in this embodiment, there are welding areas at both ends of the connecting terminal along the length direction, and there are protrusions 111 at both ends of the aluminum alloy conductor core 11 along the length direction, wherein the welding area and the protrusion 111 are welded to each other, so that a connection is formed between the connecting terminal and the aluminum alloy conductor core 11, thereby forming a conductor 1. Among them, the connecting terminal is formed by extrusion of multiple layers of copper strips, which can ensure the overall softness of the connecting terminal, so that the position between adjacent aluminum alloy conductor cores 11 can be adjusted, further improve the flexibility of the aluminum alloy cable, and facilitate automobile wiring. The two ends of the multi-layer copper strips along the length direction are connected by welding, which can ensure the stability of the structure at the connection between the connecting terminal and the aluminum alloy conductor core 11, ensure that the aluminum alloy conductor core 11 and the connecting terminal can be stably connected, and then ensure the stability of the current conduction of the conductor 1. Among them, the two ends of the multi-layer copper strip are welded as welding areas. Specifically, the two ends of the multi-layer copper strip are connected by ultrasonic welding. Of course, other welding methods can also be used, such as argon arc welding and arc welding. Of course, without considering the cost, the connecting terminal can also be formed by extruding multiple layers of silver strips. As long as the conductor 1 after the aluminum alloy conductor core 11 and the connecting terminal are assembled can conduct electricity, and the shape of the aluminum alloy cable can be adjusted, the material used for the connecting terminal is not specifically limited.

[0039] In this embodiment, the aluminum alloy cable also includes a filler 5, which is filled and arranged in the gap between the shielding layer 3 and the sheath layer 4. The addition of the filler 5 can make the aluminum alloy cable more rounded as a whole and the internal structure more compact, thereby further improving the stability of the aluminum alloy cable as a whole and increasing its service life. Among them, a non-hygroscopic material can be selected as the filler 5. The non-hygroscopic material has the characteristics of non-hygroscopicity, high flame retardancy and high strength. It can not only prevent the interior of the aluminum alloy cable from being corroded by external moisture and ensure its service life, but also can further improve the fire resistance and flame retardancy of the aluminum alloy cable. Specifically, the filler 5 can be selected from one of polypropylene rope, glass fiber rope, asbestos rope or rubber, and no specific restrictions are made here.

[0040] In this embodiment, the sheath layer 4 is made of radiation cross-linked low-smoke halogen-free flame-retardant polyolefin material, which can make the sheath layer 4 have good flame retardancy and low smoke properties, and can ensure that even if the aluminum alloy cable burns, the sheath layer 4 can self-extinguish during the combustion process. At the same time, the sheath layer 4 will not generate a large amount of heat and thick smoke during the combustion process, and the aluminum alloy cable generates low heat during the combustion process.

[0041] Preferably, the aluminum alloy cable further includes a hydrophilic coating, wherein the hydrophilic coating is coated on the outer periphery of the sheath layer 4. The hydrophilic coating can prevent external water vapor from entering the interior of the aluminum alloy cable, thereby extending the service life of the aluminum alloy cable. The hydrophilic coating can be selectively coated according to the use scenario of the aluminum alloy cable, and no specific limitation is made here.

[0042] like Figure 3 As shown, this embodiment provides a method for preparing an aluminum alloy cable, which is used to prepare an aluminum alloy cable, comprising the following steps:

[0043] Step 1: Use a lathe to turn the aluminum alloy material into a cylindrical shape; specifically, assemble the aluminum alloy material on the lathe, and then use a cutting tool to cut the aluminum alloy material into a predetermined size, wherein the predetermined size is determined according to the specification of the aluminum alloy cable.

[0044] Step 2: Use a cutting device to cut the cylindrical aluminum alloy material into a plurality of aluminum alloy guide cores 11 ; specifically, put the cylindrical aluminum alloy material into the cutting device, and the cutting device cuts it into a plurality of aluminum alloy guide cores 11 of uniform length.

[0045] Step 3: Use a connecting terminal to connect multiple aluminum alloy conductors 11 to form a conductor 1; specifically, there are protrusions 111 at both ends of the aluminum alloy conductor 11, and the two ends of the connecting terminal are respectively welded to the protrusions 111 of different aluminum alloy conductors 11 to connect the multiple aluminum alloy conductors 11 to form a conductor 1.

[0046] Step 4: coating the outer periphery of the conductor 1 with insulating material to form the insulating layer 2; specifically, extruding the ceramicized irradiated self-crosslinked polyolefin material to the outer periphery of the conductor 1 through an extruder to form the insulating layer 2.

[0047] Step 5: Wind a shielding material around the outer periphery of the insulating layer 2 to form a shielding layer 3 ; specifically, spirally wind an aluminum foil tape or a copper tape around the outer periphery of the insulating layer 2 to form a shielding layer 3 .

[0048] Step 6: Wrap the sheath material around the outer periphery of the shielding layer 3 to form the sheath layer 4. Specifically, extrude the radiation cross-linked low-smoke halogen-free flame-retardant polyolefin material to the outer periphery of the shielding layer 3 through an extruder to form the sheath layer 4.

[0049] In this embodiment, the method for manufacturing the insulating layer 2 includes the following steps:

[0050] 85-90 parts by weight of a polyolefin resin material, 0.5-2.5 parts by weight of a silane coupling agent material, 0.1-0.3 parts by weight of an initiator, 0.1-0.3 parts by weight of an antioxidant, 2-5 parts by weight of a flame retardant, 1-3 parts by weight of a filler, and 2-3 parts by weight of a ceramic material are uniformly mixed to obtain a ceramicized irradiated self-crosslinking polyolefin mixture;

[0051] Plasticizing the ceramicized irradiation self-crosslinking polyolefin mixture to obtain the ceramicized irradiation self-crosslinking polyolefin material;

[0052] The ceramicized radiation self-crosslinking polyolefin material is extruded and coated on the outer circumference of the aluminum alloy conductor core 11 to form an insulating layer 2 .

[0053] In this embodiment, the method for manufacturing the sheath layer 4 comprises the following steps:

[0054] 100 parts by weight of ethylene-vinyl acetate copolymer, 80 parts by weight of metallocene polyethylene, 190 parts by weight of aluminum hydroxide, 135 parts by weight of magnesium hydroxide, 15 parts by weight of a cross-linking agent, 65 parts by weight of a flame retardant, 12 parts by weight of an antioxidant, and 10 parts by weight of a compatibilizer are uniformly mixed to obtain a mixture of irradiation cross-linked low-smoke halogen-free flame-retardant polyolefin;

[0055] Plasticizing the mixture of radiation cross-linked low-smoke halogen-free flame-retardant polyolefin to obtain radiation cross-linked low-smoke flame-retardant polyolefin material;

[0056] The radiation cross-linked low-smoke halogen-free flame-retardant polyolefin material is extruded and coated on the outer periphery of the shielding layer 3 to form the sheath layer 4 .

[0057] It is worth noting that the weight parts mentioned in the above embodiment can be 5 grams, with a total of 100 parts, or 10 grams, with a total of 100 parts. The weight of each part can be adjusted according to actual conditions and is not limited here. The above-mentioned method is also used to match the other components. At the same time, matching the insulating layer 2 material and the sheath material based on weight parts is a conventional technical means in the chemical industry and is not the key protection scope of the present utility model.

[0058] In this embodiment, after step 6, the following steps are also included:

[0059] Filling the gap between the shielding layer 3 and the sheath layer 4 with filler 5; specifically, filling the gap between the shielding layer 3 and the sheath layer 4 with glass fiber material can not only further block external water vapor from entering the interior of the aluminum alloy cable and extend its service life, but also make the aluminum alloy cable more round and compact, improving its overall stability.

[0060] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention, and are not intended to limit the implementation methods of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the scope of protection of the present invention. It is not necessary and impossible to list all implementation methods here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention shall be included in the scope of protection of the claims of the present invention.

Claims

1. An aluminum alloy cable, characterized in that: include: A conductor (1), the conductor (1) comprising an aluminum alloy conductor core (11) and a connecting terminal, the connecting terminal being a flexible conductive part, a plurality of the aluminum alloy conductor cores (11) being provided; a plurality of the connecting terminals being provided, the plurality of connecting terminals being used to form a connection between the plurality of the aluminum alloy conductor cores (11); An insulating layer (2) covering the outer periphery of the conductor (1); A shielding layer (3) covering the outer periphery of the insulating layer (2); The sheath layer (4) is coated on the outer periphery of the shielding layer (3).

2. The aluminum alloy cable according to claim 1, characterized in that: The insulating layer (2) is made of ceramicized radiation self-crosslinking polyolefin material.

3. The aluminum alloy cable according to claim 1, characterized in that: The shielding layer (3) is formed by winding an aluminum foil tape around the outer periphery of the insulating layer (2); Alternatively, the shielding layer (3) is formed by winding a copper tape around the outer periphery of the insulating layer (2).

4. The aluminum alloy cable according to claim 1, characterized in that: The connecting terminal has welding areas at both ends along the length direction, the aluminum alloy conductor core (11) has protruding parts (111) at both ends along the length direction, and the welding areas and the protruding parts (111) are welded to each other.

5. The aluminum alloy cable according to claim 4, characterized in that: The connection terminal is formed by extruding multiple layers of copper strips, and both ends of the multiple layers of copper strips along the length direction are connected by welding, and the two ends of the multiple layers of copper strips welded are the welding areas.

6. The aluminum alloy cable according to claim 5, characterized in that: The welding method is ultrasonic welding.

7. The aluminum alloy cable according to claim 1, characterized in that: The aluminum alloy cable further comprises a filler (5), wherein the filler (5) is filled in the gap between the shielding layer (3) and the sheath layer (4).

8. The aluminum alloy cable according to claim 7, characterized in that: The filler (5) can be selected from one of polypropylene rope, glass fiber rope, asbestos rope or rubber.

9. The aluminum alloy cable according to claim 1, characterized in that: The sheath layer (4) is made of radiation cross-linked low-smoke halogen-free flame-retardant polyolefin material.

10. The aluminum alloy cable according to claim 1, characterized in that: The aluminum alloy cable also includes a hydrophilic coating, which is coated on the outer circumference of the sheath layer (4).

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