Cable and vehicle

Abstract

The utility model belongs to the technical field of cables, and particularly relates to a cable and a vehicle. The cable is sequentially provided with a conductor layer, an insulating layer, an isolating layer, a first shielding layer, a second shielding layer and a sheath from inside to outside, the conductor layer is formed by stranding a plurality of annealed copper wires; the insulating layer is made of silicone rubber resistant to 150 DEG C and is extruded outside the conductor layer; the isolating layer is made of a transparent polyester film and longitudinally wraps the insulating layer; the first shielding layer is woven into a net by tin-plated metal wires and wraps the isolating layer; the second shielding layer is made into a wrapping tape by aluminum foil mylar and then is overlapped and wrapped outside the first shielding layer; the sheath is made of a polyolefin material resistant to 150 DEG C irradiation crosslinking, and the sheath is extruded outside the second shielding layer. The conductor layer is formed by bunching and re-twisting a plurality of annealed copper wires, and is suitable for being applied to high-power vehicles; the polyolefin material resistant to 150 DEG C irradiation crosslinking is good in flexibility, wear-resistant, acid-base-resistant and aging-resistant.

Description

Technical Field

[0001] The utility model relates to the technical field of cables, in particular to a cable and a vehicle. Background Technique

[0002] With the development of transportation demands in various scenarios such as highways, ports, and mines, as well as the application of high-power power systems, high-power vehicles have become the latest market demand.

[0003] The cables for vehicles in the prior art usually adopt copper core stranded conductors, ordinary PVC extruded insulation, and sheath layers. The cables with such structures have the following disadvantages: insufficient current-carrying capacity, not suitable for high-power vehicles; poor mechanical strength and insufficient flexibility; not wear-resistant, not resistant to acids, alkalis, and salt spray; and poor shielding performance. Summary of the Utility Model

[0004] The purpose of the utility model is to provide a cable and a vehicle to solve the problems of insufficient current-carrying capacity of the cables in the prior art, not being suitable for high-power vehicles; poor mechanical strength and insufficient flexibility; not wear-resistant, not resistant to acids, alkalis, and salt spray; and poor shielding performance.

[0005] To achieve this purpose, the utility model adopts the following technical solutions:

[0006] Cable:

[0007] The cable is sequentially provided with a conductor layer, an insulating layer, an isolating layer, a first shielding layer, a second shielding layer, and a sheath from the inside to the outside;

[0008] The conductor layer is formed by bunching and then re-stranding multiple strands of annealed copper wires; the insulating layer is made of silicone rubber resistant to 150 °C and is extruded outside the conductor layer; the isolating layer is made of transparent polyester film and is longitudinally wrapped outside the insulating layer; the first shielding layer is woven into a net by tinned metal wires and is wrapped outside the isolating layer; the second shielding layer is made into a tape by aluminum foil mylar and is overlapped and wrapped outside the first shielding layer; the sheath is made of a polyolefin material irradiated and cross-linked at 150 °C, and the sheath is extruded outside the second shielding layer.

[0009] As an optional technical solution of the cable, the pitch range of the bunching is 20 mm - 50 mm.

[0010] As an optional technical solution of the cable, the pitch range of the re-stranding is 55 mm - 260 mm.

[0011] As an optional technical solution of the cable, the directions of both the bunching and the re-stranding are left-handed.

[0012] As an optional technical solution of the cable, the copper wires are drawn from copper rods, and the diameter of the copper rods is 8 mm.

[0013] As an alternative technical solution for the cable, the copper rod is an oxygen-free copper rod.

[0014] As an alternative technical solution for the cable, the thickness of the insulating layer is 1.04 mm - 1.8 mm; and / or, the thickness of the sheath is 0.96 mm - 1.70 mm.

[0015] As an alternative technical solution for the cable, the density of the braided mesh is 82% - 88%.

[0016] As an alternative technical solution for the cable, the lapping rate of the overlapping winding is at least 20% of the width of the tape.

[0017] A vehicle, applying the cable described in any one of the above.

[0018] Advantages of the present utility model:

[0019] The present utility model provides a cable and a vehicle. The cable is sequentially provided with a conductor layer, an insulating layer, an isolation layer, a first shielding layer, a second shielding layer and a sheath from the inside to the outside; the conductor layer is formed by stranding and then re-stranding a plurality of strands of annealed copper wires; the insulating layer is made of silicone rubber resistant to 150 °C and extruded around the conductor layer; the isolation layer is made of transparent polyester film and longitudinally wrapped around the insulating layer; the first shielding layer is woven into a mesh by tinned metal wires and wrapped around the outside of the isolation layer; the second shielding layer is made into a tape by aluminum foil mylar and overlapped and wound around the outside of the first shielding layer; the sheath is made of a polyolefin material resistant to 150 °C radiation cross-linking, and the sheath is extruded around the second shielding layer. The conductor layer is formed by stranding and then re-stranding a plurality of strands of annealed copper wires. The large cross-section of the conductor layer results in a large current-carrying capacity of the cable, which is suitable for high-power vehicle applications; the silicone rubber material resistant to 150 °C is soft, which can improve the flexibility of the cable, and has a high insulation volume resistivity and electrical performance, and can withstand a high instantaneous current; the transparent polyester film can prevent the first shielding layer from wearing the insulating layer and improve the insulation performance of the cable; the first shielding layer and the second shielding layer form a composite shielding, which improves the shielding performance of the cable; the polyolefin material resistant to 150 °C radiation cross-linking has good flexibility and is wear-resistant, acid and alkali resistant and aging resistant. Description of the drawings

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model, the following will briefly introduce the drawings required for the description of the embodiments of the present utility model. Obviously, the following drawings are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained according to the content of the embodiments of the present utility model and these drawings.

[0021] Figure 1 It is a cross-sectional schematic diagram of the cable provided by the embodiment of the present utility model.

[0022] In the figure:

[0023] 1. Conductor layer; 2. Insulating layer; 3. Isolation layer; 4. First shielding layer; 5. Second shielding layer; 6. Sheath. Specific embodiments

[0024] The present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the present utility model, rather than limiting the present utility model. In addition, it should be noted that for the sake of description, only parts related to the present utility model rather than all structures are shown in the accompanying drawings.

[0025] In the description of the present utility model, unless otherwise clearly defined and limited, the terms "connected", "connected", and "fixed" shall be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific situations.

[0026] In the present utility model, unless otherwise clearly defined and limited, the first feature being "above" or "below" the second feature may include direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but in contact through other features therebetween. Moreover, the first feature being "above", "over", and "on" the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature has a higher horizontal height than the second feature. The first feature being "below", "beneath", and "under" the second feature includes the first feature being directly below and obliquely below the second feature, or merely indicating that the first feature has a lower horizontal height than the second feature.

[0027] In the description of this embodiment, the orientation or positional relationships such as "above", "below", "right", etc. are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of description and simplifying the operation, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation to the present utility model. In addition, the terms "first" and "second" are only used for distinction in description and do not have special meanings.

[0028] The cables for vehicles in the prior art usually adopt copper core stranded conductors, ordinary PVC extruded insulation, and sheath layers. The cables with such structures have the following disadvantages: insufficient current-carrying capacity, not suitable for high-power vehicles; poor mechanical strength and insufficient flexibility; not wear-resistant, not resistant to acids, alkalis, and salt spray; and poor shielding performance.

[0029] Example 1:

[0030] To solve the above problems, this embodiment provides a cable. Refer to Figure 1 , the cable is sequentially provided with a conductor layer 1, an insulating layer 2, an isolating layer 3, a first shielding layer 4, a second shielding layer 5 and a sheath 6 from the inside to the outside; the conductor layer 1 is formed by bunching and then complex-stranding multiple strands of annealed copper wires; the insulating layer 2 is made of silicone rubber resistant to 150 °C and is extruded outside the conductor layer 1; the isolating layer 3 is made of transparent polyester film and longitudinally wrapped outside the insulating layer 2; the first shielding layer 4 is woven into a net by tinned metal wires and wrapped outside the isolating layer 3; the second shielding layer 5 is made of aluminum foil mylar into a tape and overlapped and wrapped outside the first shielding layer 4; the sheath 6 is made of polyolefin material irradiated and crosslinked at 150 °C, and the sheath 6 is extruded outside the second shielding layer 5.

[0031] The conductor layer 1 is formed by bunching and then complex-stranding multiple strands of annealed copper wires. The large cross-section of the conductor layer 1 results in a large current-carrying capacity of the cable, which is suitable for high-power vehicle applications; the silicone rubber material resistant to 150 °C is soft, which can improve the flexibility of the cable. The insulation volume resistivity and electrical performance are high, and it can withstand a relatively high instantaneous current; the transparent polyester film can prevent the first shielding layer 4 from wearing the insulating layer and improve the insulation performance of the cable; the first shielding layer 4 and the second shielding layer 5 form a composite shielding, which improves the shielding performance of the cable; the polyolefin material irradiated and crosslinked at 150 °C has good flexibility and is wear-resistant, acid and alkali resistant, and aging resistant.

[0032] The copper wires are drawn from copper rods, and the diameter of the copper rods is 8 mm. Preferably, the copper rods are oxygen-free copper rods. Specifically, the oxygen-free copper rods are placed in a Niehoff large drawing machine and a multi-head continuous drawing machine to obtain soft round copper single wires. The copper single wires are bunched into copper stranded wires by a bunching machine, and then the copper stranded wires are regularly stranded into the conductor layer 1 in the form of 1 + 6 + 12... by a cage stranding machine.

[0033] Among them, the annealing coefficient during wire drawing of the Niehoff drawing machine and the multi-head continuous drawing machine is 7.8 - 8.4; the take-up air pressure during wire drawing of the Niehoff drawing machine and the multi-head continuous drawing machine is 3.0 - 6.0; the diameter of the annealed soft round copper single wires is 0.1 m - 0.2 m; the bunching pitch range is 20 mm - 50 mm; the complex-stranding pitch range is 55 mm - 260 mm; the bunching direction and the complex-stranding direction are both left-handed, meeting the requirements of low-radius bending flexibility for large cross-section cables.

[0034] The conductor layer 1 provided in this embodiment can withstand a load current of 375 A at room temperature without the temperature rising by more than 40 °C; the load current reaches 745 A at the normal allowable working temperature at room temperature.

[0035] Example 2:

[0036] The structure not mentioned in this embodiment is the same as that in Example 1;

[0037] To obtain the optimal cable size, the die core size = the measured outer diameter of the conductor + the preset size; the range of the preset size is 0.4 mm - 0.6 mm; the die sleeve size = the measured outer diameter of the conductor + 2 × the nominal insulation thickness; the Sikora online side deviation monitoring is adopted to control the concentricity of the insulation. The eccentricity of the insulation will affect the working capacitance and inductance of the wire. The concentricity of the insulation layer 2 of the cable provided in this embodiment is above 95%. The silicone rubber insulation material with a heat resistance of 150°C for the insulation layer 2 solves the problem of difficult stripping of the traditional radiation-crosslinked polyolefin insulation with a heat resistance of 150°C during wire cutting, and has the following advantages compared with the traditional insulation material of radiation-crosslinked polyolefin with a heat resistance of 150°C:

[0038]

[0039] Moreover, the tear strength of the insulation layer 2 of the cable provided in this embodiment is not less than 25 N / mm.

[0040] Furthermore, the manufacturing method of the material (silicone rubber with a heat resistance of 150°C) of the insulation layer 2 includes the following steps:

[0041] S1. Open each box of packaging, take out the raw rubber, turn on the open mill, and knead 20 kg per box for 3 min - 5 min until it is evenly mixed and kneaded into a soft state;

[0042] S2. Add successively: 1.0% - 1.5% of colored rubber; 1.3% - 1.5% of Aksu DCP bis(2,4-dichlorobenzoyl) peroxide vulcanizing agent, and mix evenly until the color is uniform;

[0043] S3. Wait for the rubber strip to cool to room temperature.

[0044] The thickness of the insulation layer 2 is 1.04 mm - 1.8 mm; the body of the rubber extruder is cooled by a chiller and then vulcanized through a high-temperature drying tunnel. The vulcanization temperature zones are: Zone 1: 305°C - 315°C, Zone 2: 290°C - 305°C, Zone 3: 275°C - 290°C, Zone 4: 255°C - 275°C, Zone 5: 190°C - 205°C, Zone 6: 190°C - 205°C, Zone 7: 190°C - 205°C, Zone 8: 190°C - 205°C.

[0045] Example 3:

[0046] The structures not mentioned in this example are the same as those in Example 1 and Example 2;

[0047] The thickness of the transparent polyester film tape is 0.04 mm, and the longitudinal overlapping width is not less than 5 mm.

[0048] Example 4:

[0049] The structures not mentioned in this example are the same as those in Example 1, Example 2, and Example 3;

[0050] The tinned copper wire braided mesh is composed of tinned copper wires braided together. The braiding is carried out using a 24-spindle metal braiding machine. The diameter of the tinned copper wires is no more than 0.2 mm, and the braiding density is 82%-88%. The aluminum foil mylar tape is composed of non-hygroscopic polyester and pure aluminum foil compounded and bonded together. The thickness requirement of the aluminum foil mylar tape is 0.05 mm, and the lapping rate of the overlapping winding is at least 20% of the tape width. The aluminum foil mylar tape is evenly and overlappingly wound by a double-head winding machine with the aluminum side facing outwards, meeting the requirements of RoHS2.0 determination according to Directive 2015 / 863 / EU of RoHS. The first shielding layer 4 and the second shielding layer 5 form a composite shielding that can achieve a shielding impedance < 30 mΩ / m; the shielding attenuation ≥ 61 dB.

[0051] Example Five:

[0052] The structures not mentioned in this example are the same as those in Example One, Example Two, Example Three, and Example Four.

[0053] The sheath layer 6 is made of radiation-crosslinked polyolefin sheath material with a temperature resistance of 150°C. Before production, the sheath material should be preheated in advance. The preheating time is 90°C × 2 h to improve the extrusion fluidity of the material. The production uses an active wire feeding device, and both the wire take-up and traction are produced by a wheel-type traction machine to solve the problem of cable thermal deformation and flattening.

[0054] The body of the extruder is cooled by a chiller. From the feeding end to the discharging end, the plasticizing temperature zones are: Zone 1: 150°C - 160°C, Zone 2: 160°C - 170°C, Zone 3: 170°C - 180°C, Zone 4: 185°C - 95°C, Zone 5: 185°C - 195°C, Head Zone 1: 180°C - 190°C, Head Zone 2: 180°C - 190°C; the water tank is cooled by cooling water.

[0055] The thickness of the sheath 6 is 0.96 mm - 1.70 mm; the die core aperture = the outer diameter of the cable core + a preset size; the range of the preset size is 0.4 mm - 0.6 mm; the die sleeve aperture = the outer diameter of the cable core + 2 × the nominal thickness of the sheath.

[0056] This example also provides a vehicle that uses the above cable. This cable has good flame retardant performance, meeting the UL1581 standard VW-1 flame retardant test; excellent flexible bending performance, passing the 5000-cycle reciprocating swing test with a load of 1.0 kg / mm2, ±90°; excellent high and low temperature performance, meeting the temperature resistance performance of -50°C to +150°C; current-carrying temperature rise performance, having the characteristics of high current-carrying and low temperature rise, improving the service life of the cable; excellent electromagnetic interference effectiveness, with a shielding impedance < 30 mΩ / m and a shielding attenuation ≥ 61 dB, resisting electromagnetic interference.

[0057] Obviously, the above embodiments of the present utility model are merely examples for clearly illustrating the present utility model, rather than limitations on the implementation manners of the present utility model. For those of ordinary skill in the art, various obvious changes, re-adjustments and substitutions can be made without departing from the protection scope of the present utility model. It is not necessary and impossible to enumerate all the implementation manners here. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present utility model shall be included within the protection scope of the claims of the present utility model.

Claims

1. A cable, characterized in that The cable is sequentially provided with a conductor layer (1), an insulating layer (2), an isolation layer (3), a first shielding layer (4), a second shielding layer (5) and a sheath (6) from the inside to the outside; The conductor layer (1) is formed by bundling and twisting a plurality of annealed copper wires; The insulating layer (2) is made of silicone rubber resistant to 150° C. and is extruded onto the outside of the conductor layer (1); The isolation layer (3) is made of a transparent polyester film and is longitudinally wrapped around the outside of the insulating layer (2); The first shielding layer (4) is made of tinned metal wires woven into a mesh and wrapped around the outside of the isolation layer (3); The second shielding layer (5) is made of aluminum foil Mylar tape and then wrapped around the outside of the first shielding layer (4). The sheath (6) is made of a polyolefin material resistant to 150° C. radiation cross-linking, and the sheath (6) is extruded onto the outside of the second shielding layer (5).

2. The cable according to claim 1, characterized in that The pitch range of the bundle is 20mm-50mm.

3. The cable according to claim 1, characterized in that The pitch range of the re-twisting is 55mm-260mm.

4. The cable according to claim 1, characterized in that The bundling direction and the re-twisting direction are both left-handed.

5. The cable according to claim 1, characterized in that The copper wire is drawn from a copper rod, and the diameter of the copper rod is 8 mm.

6. The cable according to claim 5, characterized in that The copper rod is an oxygen-free copper rod.

7. The cable according to any one of claims 1 to 6, characterized in that: The thickness of the insulating layer (2) is 1.04 mm-1.8 mm; and / or the thickness of the sheath (6) is 0.96 mm-1.70 mm.

8. The cable according to any one of claims 1 to 6, characterized in that: The density of the woven mesh is 82%-88%.

9. The cable according to any one of claims 1 to 6, characterized in that: The overlapping rate of the overlapping wrapping is at least 20% of the width of the wrapping tape.

10. A vehicle, characterized in that Application of the cable as described in any one of claims 1 to 9.

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