High-temperature-resistant and high-pressure-resistant super-soft connecting wire for new energy

Abstract

The utility model provides a high-temperature-resistant and high-pressure-resistant super-soft connecting wire for a new energy vehicle, which improves the heat resistance and the pressure resistance of the connecting wire, ensures the performance of the connecting wire to be maintained, has good flexibility and bendability, is convenient for wiring in a narrow space in the vehicle, and comprises a core wire, a flame-retardant filler, a shielding layer and a sheath layer are sequentially coated outside the core wire from inside to outside, the core wire comprises an inner conductor, the inner conductor is formed by compositely twisting a plurality of strands of bare copper wires or tinned copper wires, and a conductor filler is filled in an internal gap of the core wire; the insulating layer is made of silicon rubber, and the outer side of the inner conductor is wrapped with the insulating layer; the shielding layer is formed by weaving bare copper wires or tinned copper wires; the sheath layer adopts a cross-linked polyethylene sheath; the cable further comprises a wrapping tape layer, the wrapping tape layer is located on the inner side or the outer side of the shielding layer, the wrapping tape layer is made of aluminum foil mylar, and the wrapping tape layer makes contact with the shielding layer and is conducted with the shielding layer.

Description

Technical Field

[0001] The utility model relates to a cable, in particular to a high-temperature and high-pressure resistant and ultra-soft connecting wire for new energy vehicles. Background Technique

[0002] With the country's strong advocacy of the sustainable development strategy and the rise of new energy projects, new energy vehicles, as an important energy technology, have been widely promoted across the country and even globally. Due to the booming development of the new energy vehicle market, the performance requirements for vehicle interior accessories are also increasing day by day. Among them, as one of the key components, the performance of the connecting wire is directly related to the safety and efficiency of the whole vehicle.

[0003] As an important part of the vehicle interior electrical system, the connecting wire is responsible for transmitting electrical energy and signals, and its quality and performance are directly related to the operation stability, energy efficiency and safety of new energy vehicles. However, traditional connecting wires have obvious deficiencies in high-temperature and high-pressure resistance and flexibility, and cannot meet the growing performance requirements of new energy vehicles.

[0004] First of all, the ability to withstand high temperature and high pressure is an important challenge that the connecting wire must face in new energy vehicles. Core components such as motors and batteries in new energy vehicles will generate high temperatures and pressures during operation, which puts higher requirements on the heat resistance and pressure resistance of the connecting wire. However, existing connecting wires are prone to aging, deformation and even fracture in high-temperature and high-pressure environments, which will not only affect the normal operation of the vehicle, but may also cause serious safety hazards.

[0005] Secondly, the flexibility of the connecting wire is also an important factor restricting the development of new energy vehicles. The interior space of new energy vehicles is compact and the wiring is difficult, which requires the connecting wire to have good flexibility so as to be flexibly wired in a narrow space. However, existing connecting wires often have insufficient flexibility due to material or process limitations, which brings great trouble to the wiring work. Content of the Utility Model

[0006] In view of the above problems, the utility model provides a high-temperature and high-pressure resistant and ultra-soft connecting wire for new energy vehicles, which improves the heat resistance and pressure resistance of the connecting wire, and at the same time ensures that the connecting wire has good flexibility and bendability while maintaining its performance, so as to facilitate wiring in the narrow space inside the vehicle.

[0007] Its technical solution is as follows: a high-temperature and high-pressure resistant and ultra-soft connecting wire for new energy vehicles, including:

[0008] A core wire, the outside of which is sequentially coated with a flame-retardant filler, a shielding layer and a sheath layer from inside to outside, and is characterized in that:

[0009] The core wire includes:

[0010] An inner conductor, which is formed by composite stranding of multiple strands of bare copper wires or tinned copper wires, and a conductor filler is filled in the internal gap of the core wire;

[0011] An insulating layer, which is made of silicone rubber and wraps around the outside of the inner conductor;

[0012] The shielding layer is woven from bare copper wires or tinned copper wires;

[0013] The sheath layer is made of cross-linked polyethylene sheath;

[0014] It further includes a tape layer, which is located inside or outside the shielding layer. The tape layer is made of aluminum foil mylar and is in contact with and conducts electricity to the shielding layer.

[0015] Further, the flame retardant filler is a soft filler.

[0016] Further, the conductor filler is any one of Kevlar fibers, copper foil wires, and nylon wires.

[0017] Further, the braiding density of the shielding layer is not less than 85%.

[0018] Further, the overlapping rate of the tape layer is not less than 20%.

[0019] Further, the thinnest point of the thickness of the sheath layer is not less than 1 mm.

[0020] Further, the insulating layer is made of soft silicone rubber, the working temperature meets -40°C to 180°C, and the thinnest point of the thickness of the insulating layer is greater than or equal to 0.8 mm.

[0021] Further, two or more core wires are provided.

[0022] Further, the inner conductor adopts a Class 6 conductor.

[0023] The high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire provided by the utility model selects silicone rubber and cross-linked polyethylene with high temperature resistance and high pressure resistance for the insulating layer and the sheath layer respectively, so that the connecting wire can maintain a stable working state in an extremely high-temperature and high-pressure environment. This not only ensures the running stability of new energy vehicles in harsh working environments, but also greatly reduces the potential safety hazards caused by wire aging or breakage. The core wire of the utility model is formed by composite twisting of multiple strands of wires, and a conductor filler is added during the twisting process of the core wire to enhance the tensile strength of the wire. Moreover, the gaps formed by the composite twisting of the core wire provide space for bending, improving the flexibility of the connecting wire. In addition, the insulating layer uses soft silicone rubber and the flame retardant filler uses a soft filler, so that while maintaining high performance, the connecting wire exhibits excellent softness and bendability. This enables the connecting wire to be flexibly routed in the narrow space inside new energy vehicles, greatly reducing the wiring difficulty and cost and improving work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 Schematic diagram of the two-core high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in the embodiment;

[0025] Figure 2 Schematic diagram of the three-core high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in another embodiment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] As described in the background art, in view of the deficiencies in high temperature resistance and softness of the existing new energy vehicle connecting wires in the design, the utility model provides a high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire. As Figure 1 , a high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in this embodiment includes:

[0027] Core wire 1. In this embodiment, there are two core wires 1. The outside of the core wire 1 is sequentially coated with a flame retardant filler 2, a shielding layer 3, and a sheath layer 4 from the inside to the outside. Among them, the core wire 1 includes:

[0028] Inner conductor 101, which is formed by composite twisting of multiple strands of bare copper wires or tinned copper wires, and a conductor filler 102 is filled in the internal gap of the core wire;

[0029] Insulating layer 103, which uses silicone rubber, and the insulating layer 103 is wrapped outside the inner conductor 101;

[0030] The shielding layer 3 is woven with bare copper wires or tinned copper wires;

[0031] The sheath layer 4 uses a cross-linked polyethylene sheath;

[0032] It also includes a tape layer 5 which is located inside the shielding layer 3. The tape layer 5 is made of aluminum foil mylar and is in contact with and electrically conductive to the shielding layer.

[0033] In Figure 1 the illustrated embodiment, there are two core wires 1. The inner conductor 101 of the core wire 1 is made of bare copper or tinned copper and is stranded, meeting the requirements of Class 6 conductor structure in GB / T 3956 - 2008. Its composition, performance, and appearance comply with the provisions of GB / T 3956 - 2008 standard. The copper wire used for the inner conductor 101 is a single wire with a smooth surface, no oil stain, no burrs damaging the insulation, no sharp edges, and no protrusions or breaks. In the embodiment, the inner conductor 101 adopts a multi-strand composite stranding form to ensure its roundness and softness.

[0034] In the embodiment, the conductor filler 102 can be any one of Kevlar fiber, copper foil wire, and nylon wire. While ensuring softness, the conductor filler plays a role in strengthening the tensile strength of the wire. The conductor filler can be stranded together with the multi-strand conductors of the inner conductor 101.

[0035] In the embodiment, the insulation layer 103 uses highly flexible silicone rubber insulation, whose performance complies with the provisions of QC / T 1037 - 2016 standard. The operating temperature meets - 40°C to 180°C. The insulation layer 103 is tightly extruded on the inner conductor 101. The insulation surface is smooth, flat, with uniform color. There are no defects such as visible bubbles and sand holes in the cross-section. The thinnest point of the insulation layer thickness is greater than or equal to 0.8 mm.

[0036] In the embodiment, the flame retardant filler 2 can adopt a flame retardant PP filling rope or other flexible fillers, such as flame retardant cotton thread, fiberglass rope, and expanded polypropylene filler.

[0037] In the embodiment, the tape layer 5 is made of aluminum foil mylar, which plays a role in protecting the silicone rubber insulation and electromagnetic shielding. It can effectively block external interference signals and ensure the normal operation of the equipment. Whether the tape layer 5 is inside or outside the shielding layer 3, its aluminum layer is in contact with and electrically conductive to the shielding layer 3. The overlap rate of the tape layer is not less than 20%. The shielding layer 3 is made of bare copper wire or tinned copper wire braided, and the braiding density should not be less than 85%.

[0038] In the embodiment, the sheath layer 4 mainly uses cross-linked polyethylene suitable for the operating temperature of the cable, which has the advantages of high and low temperature resistance, high flexibility, oil and water resistance, acid and alkali resistance, abrasion resistance, anti-cracking, anti-UV, and flame retardancy. The sheath layer 4 is tightly extruded on the shielding layer or the tape layer and is easy to peel off without damaging the insulator or the shielding layer. The sheath surface is flat and the color is uniform. The thinnest point of the sheath layer 4 thickness is not less than 1 mm.

[0039] In the embodiment, a double-core high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire is provided. In other embodiments, it can also be configured as a high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire with more than two cores, such as Figure 2 As shown, in this embodiment, a three-core high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire is provided. Different from the Figure 1 solution is also that the tape layer 5 is located outside the shielding layer 3.

[0040] The high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in the embodiment is made into a product for testing, which can be sampled by batch or continuously. The sampling quantity should be not less than 10% or not less than 3 pieces. After testing, the standard rated temperature of the product can reach -40°C to 125°C or higher, and the rated voltage can reach 1000VAC / 1500VDC. The finished cable can withstand an AC 50HZ test voltage of 5kV for 5 minutes without insulation breakdown.

[0041] The high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in the embodiment has a relatively simple structure. The insulating layer and the sheath layer respectively use high-temperature and high-pressure resistant silicone rubber and cross-linked polyethylene, thereby improving the overall performance of the wire. This enables the new energy vehicle connecting wire to be improved in terms of vehicle safety, efficient processing, reliability, and durability, allowing the connecting wire to maintain a stable working state in extremely high-temperature and high-pressure environments. This not only ensures the running stability of new energy vehicles in harsh working environments but also greatly reduces potential safety hazards caused by wire aging or breakage. At the same time, the connecting wire provided in the embodiment has excellent flexibility. While maintaining high performance, the connecting wire exhibits excellent flexibility and bendability. This enables the connecting wire to be flexibly routed in the narrow space inside new energy vehicles, greatly reducing the wiring difficulty and cost and improving work efficiency. The conventional new energy vehicle connecting wire has an XLPE+XLPE structure, and the material is relatively hard and not easy to process. The hardness is typically around 88±3A. In the high-temperature and high-pressure resistant ultra-soft new energy vehicle connecting wire in the embodiment, the conductor uses a thinner Class 6 conductor and a combination of insulating silicone rubber + XLPE sheath, reflecting flexibility and safety in terms of conductor and insulation material selection. The hardness is much lower than 88A. The sheath only serves a protective function, so inexpensive XLPE (cross-linked polyethylene) is selected, reflecting economy.

[0042] Due to the improvement in high-temperature and high-pressure resistance performance, the connecting wire can work stably in more severe environments, reducing the occurrence of failures caused by wire aging or breakage. At the same time, the improvement in flexibility also makes wiring more flexible and convenient, reducing the wiring difficulty and cost. Secondly, this new type of connecting wire can also extend the service life of new energy vehicles. Since the number of failures and repairs caused by wire problems is reduced, the reliability and durability of the vehicle are improved.

[0043] In addition, the connecting wires in the embodiments also have excellent electrical performance. The dielectric strength of the insulating silicone rubber for electrical performance has been tested to be 25 - 30 KV / mm, which is much better than other materials. It can effectively transmit electric energy and signals, ensuring the normal operation of the electrical system of new energy vehicles. At the same time, its characteristics of low resistance and low loss also help to improve the energy efficiency of the vehicle and reduce energy waste.

[0044] The connecting wires of the present utility model also have excellent performance in terms of environmental protection. The materials of the connecting wires are environmentally friendly materials, all of which are halogen-free and antimony-free materials, meeting the domestic and international environmental protection requirements of RoHS and REACH, minimizing the impact on the environment during the production and use of the connecting wires, and meeting the current social requirements for green and sustainable development.

[0045] For those skilled in the art, it is obvious that the present utility model is not limited to the details of the above-described exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic characteristics of the present utility model. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present utility model is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present utility model.

[0046] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-temperature and high-pressure resistant, ultra-soft connecting wire for new energy vehicles, comprising: A core wire, on the outer part of which there are successively coated, from inside to outside, a flame-retardant filler, a shielding layer, and a sheath layer. It is characterized in that: The core wire includes: An inner conductor, which is formed by composite stranding of multiple strands of bare copper wires or tinned copper wires, and a conductor filler is filled in the inner gap of the core wire; An insulating layer, which uses silicone rubber, and the insulating layer wraps around the outside of the inner conductor; The shielding layer is woven from bare copper wires or tinned copper wires; The sheath layer uses a cross-linked polyethylene sheath; It further includes a tape layer, which is located inside or outside the shielding layer. The tape layer uses aluminum foil mylar, and the tape layer is in contact with and conducts electricity with the shielding layer; The flame-retardant filler uses a soft filler, and there are two or more core wires; The insulating layer uses soft silicone rubber, and the working temperature meets -40°C to 180°C; The inner conductor uses a Class 6 conductor.

2. The high-temperature and high-pressure resistant and ultra-soft new energy vehicle connecting wire according to claim 1, characterized in that: The conductor filler uses any one of Kevlar fibers, copper foil wires, and nylon wires.

3. The high-temperature and high-pressure resistant ultra-soft new energy vehicle connection line according to claim 1, characterized in that: The braiding density of the shielding layer is not less than 85%.

4. A high-temperature and high-pressure resistant and ultra-soft new energy vehicle connection line according to claim 1, characterized in that: The overlapping rate of the tape layer is not less than 20%.

5. The high-temperature and high-pressure resistant and super-soft new energy vehicle connection line according to claim 1, wherein: The thinnest point of the thickness of the sheath layer is not less than 1 mm.

6. A high-temperature and high-pressure resistant and ultra-soft new energy vehicle connection wire according to claim 1, characterized in that: The thinnest point of the thickness of the insulating layer is greater than or equal to 0.8 mm.

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