Aluminum conductor flexible flat cable (FFC) wire harness

Abstract

The utility model relates to the technical field of wire harnesses, and discloses an aluminum conductor FFC wire harness, which comprises an insulating base body, a plurality of flat wires are embedded in the insulating base body, the flat wires are made of aluminum materials or aluminum foil mylar, fuse structures are arranged on the flat wires, and two ends of each flat wire are exposed out of the insulating base body. The aluminum conductor FFC wire harness provided by the utility model solves the problems that the width of a fuse made of copper in the prior art is small, the weight of the whole wire harness is heavy, and the wire harness can not be directly welded with an aluminum bar of a CCS.

Description

Technical Field

[0001] The utility model relates to the technical field of wire harnesses, in particular to an aluminum conductor FFC wire harness. Background Art

[0002] The conductors used in mainstream wiring harnesses on the market (FPC, FDC, PCB, FFC, FIC, and electronic wiring harnesses) are metal copper wire or tinned copper wire. FPC, FDC, and PCB are made by etching copper sheets into circuits. During the etching process, some areas are etched very thinly to create a fuse effect. FFC uses welding to weld an FPC or FDC with a fuse. FIC uses roll cutting to cut the conductor into thin pieces to create a fuse effect. Electronic wiring harnesses have an additional fuse welded on. A fuse blows when current flows through the fuse, generating heat that reaches the conductor's melting point, causing it to break.

[0003] Copper metal is relatively heavy and expensive, with a density of 8.960g / cm 3 The melting point of copper is 1083.4℃, so when using copper wire or tinned copper wire to make fuses, the width of the fuse should not be too large, such as Figure 1 As shown, the weight of the entire wiring harness is relatively heavy, and it cannot be directly welded to the aluminum busbar of CCS. It is necessary to weld nickel sheets, or crimp nickel sheets, or crimp aluminum terminals for transfer, and then weld them to the aluminum busbar of CCS, so that the battery voltage can be collected. Utility Model Content

[0004] The purpose of the utility model is to provide an aluminum conductor FFC wiring harness to solve at least one of the above-mentioned problems existing in the prior art.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] An aluminum conductor FFC wiring harness includes an insulating base, in which a plurality of flat wires are embedded. The flat wires are made of aluminum or aluminum foil Mylar. A fuse structure is provided on the flat wires. Both ends of the plurality of flat wires are exposed from the insulating base.

[0007] In this technical solution, since the melting point of aluminum is 660°C, the resistivity of aluminum (20 degrees Celsius) is 0.0283 ohm.mm 2 / m, while the resistivity of copper (20 degrees Celsius) is 0.0185 ohm.mm 2 / m. Therefore, given the same cross-sectional area, aluminum has a higher resistance and a lower melting point. Therefore, the wire width at the fuse can be thicker, rather than as thin as copper wire. When using aluminum foil Mylar as the conductor, the Mylar at the fuse also provides strong protection against conductor breakage. Aluminum or aluminum foil Mylar conductors can be directly welded to the CCS aluminum busbar using ultrasonic welding, soldering iron welding, laser welding, and other methods. This eliminates the need for additional media for connection, reducing materials and processes, and ultimately lowering overall cost and weight.

[0008] Furthermore, the aluminum foil Mylar layer includes a Mylar layer, a glue layer and an aluminum or aluminum foil layer arranged in sequence.

[0009] Furthermore, the insulating matrix includes an outer insulating layer and an intermediate adhesive layer, and the flat wire is embedded in the intermediate adhesive layer.

[0010] Furthermore, the insulating layer is made of PET, PI or PO.

[0011] The beneficial effects of the present invention are as follows: In this technical solution, since the melting point of aluminum is 660°C, the resistivity of aluminum (20°C) is 0.0283 ohm.mm 2 / m, while the resistivity of copper (20 degrees Celsius) is 0.0185 ohm.mm 2 / m. Therefore, given the same cross-sectional area, aluminum has a higher resistance and a lower melting point. Therefore, the wire width at the fuse can be thicker, rather than as thin as copper wire. When using aluminum foil Mylar as the conductor, the Mylar at the fuse also provides strong protection against conductor breakage. Aluminum or aluminum foil Mylar conductors can be directly welded to the CCS aluminum busbar using ultrasonic welding, soldering iron welding, laser welding, and other methods. This eliminates the need for additional media for connection, reducing materials and processes, and ultimately lowering overall cost and weight. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is a schematic diagram of the structure of a copper fuse in the prior art;

[0013] Figure 2 This is a schematic diagram of the main structure of the utility model;

[0014] Figure 3 This is a schematic diagram of the top structure of the utility model;

[0015] Figure 4 Based Figure 3 Schematic diagram of the cross-sectional structure of AA;

[0016] Figure 5 This is a schematic diagram of the structure of the aluminum foil Mylar in the utility model;

[0017] Figure 6 This is a schematic structural diagram of a fuse using aluminum and aluminum foil Mylar as conductors in the present invention.

[0018] In the figure: insulating base 1; outer insulating layer 1.1; middle glue layer 1.2; flat wire 2; fuse structure 3; Mylar layer 4; glue layer 5; aluminum or aluminum foil layer 6. DETAILED DESCRIPTION

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the present invention will be briefly introduced below in conjunction with the drawings and the description of the embodiments or the prior art. Obviously, the following description of the structures of the drawings is only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work. It should be noted that the description of these embodiments is used to help understand the present invention, but does not constitute a limitation of the present invention.

[0020] Example 1:

[0021] like Figure 2-Figure 6 As shown, this embodiment provides an aluminum conductor FFC harness, including an insulating base 1, in which a plurality of flat wires 2 are embedded. The flat wires 2 are made of aluminum or aluminum foil Mylar. A fuse structure 3 is provided on the flat wire 2, and both ends of the plurality of flat wires 2 are exposed from the insulating base 1.

[0022] In this technical solution, since the melting point of aluminum is 660°C, the resistivity of aluminum (20 degrees Celsius) is 0.0283 ohm.mm 2 / m, while the resistivity of copper (20 degrees Celsius) is 0.0185 ohm.mm 2 / m, therefore, under the same cross-sectional area, the resistance of aluminum will be higher, and the melting point of aluminum is lower, so the wire width at the fuse can be made thicker, such as Figure 6 As shown, it does not need to be made as thin as copper wire. Copper wire fuses are Figure 1 As shown, when using aluminum foil Mylar as the conductor, the Mylar at the fuse provides strong protection against conductor breakage. Aluminum or aluminum foil Mylar as the conductor can be directly welded to the CCS aluminum busbar. Ultrasonic welding, soldering iron welding, laser welding, and other methods are possible. No additional media is required for connection, reducing materials and processes, ultimately lowering overall cost and weight.

[0023] like Figure 5 As shown, the aluminum foil Mylar comprises a Mylar layer 4, an adhesive layer 5 and an aluminum or aluminum foil layer 6 which are arranged in sequence.

[0024] like Figure 4As shown, the insulating base 1 includes an outer insulating layer 1.1 and an intermediate adhesive layer 1.2, and the flat conductor 2 is embedded in the intermediate adhesive layer 1.2.

[0025] The insulation layer is made of PET, PI or PO.

[0026] It should be noted that this technical solution uses aluminum or aluminum foil Mylar instead of copper wire and tinned copper wire to collect battery voltage. The battery temperature collection circuit can continue to use tinned copper wire or copper wire. Scope of application: FFC and CCS of temperature and voltage signal collection lines in new energy vehicle batteries and energy storage batteries.

[0027] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. An aluminum conductor FFC harness, characterized by: It includes an insulating base, in which a plurality of flat wires are embedded. The flat wires are made of aluminum or aluminum foil Mylar. A fuse structure is provided on the flat wires, and both ends of the plurality of flat wires are exposed from the insulating base.

2. The aluminum conductor FFC harness according to claim 1, characterized in that: The aluminum foil Mylar layer comprises a Mylar layer, a glue layer and an aluminum or aluminum foil layer which are arranged in sequence.

3. The aluminum conductor FFC harness according to claim 1, characterized in that: The insulating matrix includes an outer insulating layer and an intermediate adhesive layer, and the flat wire is embedded in the intermediate adhesive layer.

4. The aluminum conductor FFC harness according to claim 3, characterized in that: The insulating layer is made of PET, PI or PO material.

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