Bending-resistant vehicle cable

Abstract

The utility model discloses a bending-resistant cable for a vehicle, and relates to the technical field of cables. The cable comprises a conductor, wherein an inner insulating layer, a metal shielding layer, a filling layer, an outer insulating layer, a buffer layer, a wrapping tape and a sheath layer are sequentially arranged outside the conductor. According to the utility model, the conductor structure is optimized, and the multi-layer composite insulation and reinforced buffer design is adopted, so that the cable can bear a large number of times of bending and twisting, and the service life is prolonged; the high braiding density of the metal shielding layer effectively shields external electromagnetic interference, and ensures the accuracy and stability of signal transmission. Due to the high temperature resistance of the inner insulating layer and the low temperature resistance of the outer insulating layer, the cable can work normally under an extreme temperature condition. The material selection of the filling layer and the buffer layer enhances the resistance of the cable to vibration and impact; through reasonable structural design and material selection, the cable has good flexibility and wear resistance, wiring and installation in a vehicle are facilitated, and the maintenance cost is reduced at the same time.

Description

Technical Field

[0001] The utility model belongs to the technical field of cables, and in particular relates to a bending-resistant vehicle cable. Background Art

[0002] With the rapid development of the automotive industry, performance requirements for automotive cables are increasing. In particular, during vehicle operation, cables are frequently subjected to mechanical stresses such as bending and torsion. Therefore, flex resistance has become a key quality indicator for automotive cables. Existing automotive cables often lack flex resistance, making them prone to conductor breakage and insulation damage over long-term use. This can impact the normal operation of the vehicle's electrical system and even pose safety risks.

[0003] Currently, no effective solutions have been proposed for the problems in related technologies. Utility Model Content

[0004] In response to the problems in the related art, the present invention proposes a bending-resistant vehicle cable to overcome the above-mentioned technical problems existing in the existing related art.

[0005] In order to solve the above technical problems, the present invention is achieved through the following technical solutions:

[0006] The utility model is a bending-resistant vehicle cable, comprising a conductor, wherein an inner insulating layer, a metal shielding layer, a filling layer, an outer insulating layer, a buffer layer, a tape and a sheath layer are sequentially arranged on the outside of the conductor, wherein the inner insulating layer is tightly wrapped around the outside of the conductor, the metal shielding layer is arranged outside the inner insulating layer, the filling layer is filled between the metal shielding layer and the outer insulating layer, the outer insulating layer is wrapped around the filling layer, the buffer layer is arranged outside the outer insulating layer, the tape is wrapped around the buffer layer, and the sheath layer is arranged outside the tape.

[0007] Furthermore, the inner insulating layer is made of high-temperature resistant cross-linked polyethylene, and its thickness is uniform and not less than 0.5 mm.

[0008] Furthermore, the metal shielding layer is woven from tinned copper wires, and the weaving density is not less than 85%.

[0009] Furthermore, the filling layer is made of elastic rubber material, and a plurality of hollow elastic fiber tubes are evenly distributed in the filling layer.

[0010] Furthermore, the outer insulating layer is made of low-temperature resistant silicone rubber and has a thickness of not less than 1 mm.

[0011] Furthermore, the buffer layer is made of polyurethane foam and has a thickness of not less than 0.8 mm.

[0012] Furthermore, the wrapping tape is a PTFE microporous foam insulation tape with an overlap rate of more than 30%.

[0013] Furthermore, the sheath layer is made of wear-resistant and oil-resistant chlorinated polyethylene, and its thickness is not less than 1.5 mm.

[0014] Furthermore, the conductor consists of a pair of DC power core wires, a pair of signal control core wires, a pair of data transmission core wires and a protective grounding core wire, and the DC power core wires, signal control core wires, data transmission core wires and protective grounding core wires are all made of multiple strands of finely twisted silver-plated copper wires.

[0015] The utility model has the following beneficial effects:

[0016] 1. The utility model optimizes the conductor structure, adopts multi-layer composite insulation and strengthens the buffer design, so that the cable can withstand a large number of bending and twisting times, thereby extending its service life.

[0017] 2. This utility model effectively shields external electromagnetic interference through the high braid density of the metal shielding layer, ensuring accurate and stable signal transmission. The high-temperature resistance of the inner insulation layer and the low-temperature resistance of the outer insulation layer enable the cable to operate normally under extreme temperature conditions. The material selection of the filler layer and the buffer layer enhances the cable's resistance to vibration and impact. The rational structural design and material selection give the cable excellent flexibility and wear resistance, facilitating wiring and installation within vehicles while reducing maintenance costs.

[0018] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the utility model, the following is a brief introduction to the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0020] Figure 1 This is a layered structure diagram of the present utility model.

[0021] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0022] 1. Conductor; 2. Inner insulation layer; 3. Metal shielding layer; 4. Filling layer; 5. Outer insulation layer; 6. Buffer layer; 7. Tape; 8. Jacket layer. DETAILED DESCRIPTION

[0023] The following will clearly and completely describe the technical solutions in the utility model embodiments in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the utility model embodiments, not all of the embodiments. Based on the utility model embodiments, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of utility model protection.

[0024] In the description of the present utility model, it should be understood that the terms "opening", "upper", "lower", "top", "middle", "inside" and the like indicating orientation or positional relationship are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the utility model.

[0025] See also Figure 1 As shown, the utility model is a bending-resistant automotive cable, comprising a conductor 1, on the outside of which are sequentially arranged an inner insulating layer 2, a metal shielding layer 3, a filling layer 4, an outer insulating layer 5, a buffer layer 6, a tape 7 and a sheath layer 8, wherein the inner insulating layer 2 is tightly wrapped around the outside of the conductor 1, the metal shielding layer 3 is arranged outside the inner insulating layer 2, the filling layer 4 is filled between the metal shielding layer 3 and the outer insulating layer 5, the outer insulating layer 5 is wrapped around the filling layer 4, the buffer layer 6 is arranged outside the outer insulating layer 5, the tape 7 is wrapped around the buffer layer 6, and the sheath layer 8 is arranged outside the tape 7.

[0026] The above design increases the flexibility and conductivity of the conductor, and the silver plating treatment improves the corrosion resistance.

[0027] In one embodiment, the inner insulating layer 2 is made of high-temperature-resistant cross-linked polyethylene and has a uniform thickness of no less than 0.5 mm, ensuring excellent insulation performance even in high-temperature environments. Based on the operating temperature and insulation requirements of automotive cables, experimental and theoretical calculations have shown that a thickness of 0.5 mm provides sufficient insulation strength and high-temperature resistance.

[0028] In one embodiment, the metal shielding layer 3 is woven from tinned copper wire with a braid density of no less than 85%. This effectively shields against external electromagnetic interference and ensures stable signal transmission. Electromagnetic compatibility testing and simulation analysis have shown that a braid density of 85% effectively shields against most external electromagnetic interference, ensuring the normal operation of in-vehicle electronic devices.

[0029] In one embodiment, the filling layer 4 is made of an elastic rubber material, and a plurality of hollow elastic fiber tubes are evenly distributed within the filling layer 4. This structure reduces the weight of the cable while enhancing the cable's compression resistance and resilience, thereby improving its bending resistance.

[0030] In one embodiment, the outer insulating layer 5 is made of low-temperature-resistant silicone rubber and has a thickness of no less than 1 mm. Performance tests in low-temperature environments have shown that a thickness of 1 mm ensures that the outer insulating layer does not become brittle or crack under extreme low-temperature conditions, maintaining good insulation performance.

[0031] In one embodiment, the buffer layer 6 is made of polyurethane foam and has a thickness of not less than 0.8 mm. Mechanical performance tests have shown that the 0.8 mm buffer layer can effectively absorb and cushion vibrations and shocks during vehicle operation, protecting the internal structure.

[0032] In one embodiment, the wrapping tape 7 is a PTFE microporous foam insulation tape with an overlap ratio of at least 30%. This further enhances insulation performance and reduces friction between the sheath and the internal structure. Testing of insulation performance and abrasion resistance of wrapping tapes with varying overlap ratios revealed that an overlap ratio of at least 30% significantly improved the cable's insulation performance and abrasion resistance.

[0033] In one embodiment, the sheath layer 8 is made of wear-resistant and oil-resistant chlorinated polyethylene and has a thickness of no less than 1.5 mm. Based on simulation tests of wear and oily environments experienced in vehicle use, a thickness of 1.5 mm provides adequate protection for the cable and extends its service life.

[0034] In one embodiment, for the above-mentioned conductor 1, the conductor 1 is composed of a pair of DC power core wires, a pair of signal control core wires, a pair of data transmission core wires and a protective grounding core wire, and the DC power core wires, signal control core wires, data transmission core wires and protective grounding core wires are all made of multiple strands of finely twisted silver-plated copper wires.

[0035] The above technical solution achieves this by: 1. By optimizing the conductor structure, adopting multi-layer composite insulation, and enhancing the buffer design, the cable can withstand a large number of bends and twists, thereby extending its service life. 2. The high braid density of the metal shield effectively shields against external electromagnetic interference, ensuring accurate and stable signal transmission. The high-temperature resistance of the inner insulation layer and the low-temperature resistance of the outer insulation layer enable the cable to operate normally in extreme temperature conditions. The material selection of the filler layer and the buffer layer enhances the cable's resistance to vibration and impact. The rational structural design and material selection give the cable excellent flexibility and wear resistance, facilitating wiring and installation within the vehicle while reducing maintenance costs.

[0036] Throughout this specification, references to terms such as "one embodiment," "example," or "specific example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the utility model. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0037] The preferred embodiments of the utility model disclosed above are intended only to help illustrate the utility model. The preferred embodiments do not describe all details in detail, nor do they limit the utility model to the specific embodiments described. Obviously, many modifications and variations are possible based on the content of this specification. This specification selects and describes these embodiments in detail to better explain the principles and practical applications of the utility model, thereby enabling those skilled in the art to better understand and utilize the utility model. The utility model is limited only by the claims and their full scope and equivalents.

Claims

1. A bending-resistant vehicle cable, comprising a conductor (1), characterized in that: An inner insulating layer (2), a metal shielding layer (3), a filling layer (4), an outer insulating layer (5), a buffer layer (6), a wrapping tape (7) and a sheath layer (8) are sequentially arranged outside the conductor, wherein the inner insulating layer (2) is tightly wrapped outside the conductor (1), the metal shielding layer (3) is arranged outside the inner insulating layer (2), the filling layer (4) is filled between the metal shielding layer (3) and the outer insulating layer (5), the outer insulating layer (5) is wrapped outside the filling layer (4), the buffer layer (6) is arranged outside the outer insulating layer (5), the wrapping tape (7) is wrapped outside the buffer layer (6), and the sheath layer (8) is arranged outside the wrapping tape (7).

2. The bending-resistant vehicle cable according to claim 1, characterized in that: The inner insulating layer (2) is made of high-temperature resistant cross-linked polyethylene and has a uniform thickness of not less than 0.5 mm.

3. The bending-resistant vehicle cable according to claim 1, characterized in that: The metal shielding layer (3) is woven from tinned copper wires, with a weaving density of not less than 85%.

4. The bending-resistant vehicle cable according to claim 1, characterized in that: The filling layer (4) is made of elastic rubber material, and a plurality of hollow elastic fiber tubes are evenly distributed in the filling layer (4).

5. The bending-resistant vehicle cable according to claim 1, characterized in that: The outer insulating layer (5) is made of low-temperature resistant silicone rubber and has a thickness of not less than 1 mm.

6. The bending-resistant vehicle cable according to claim 1, characterized in that: The buffer layer (6) is made of polyurethane foam and has a thickness of not less than 0.8 mm.

7. The bending-resistant vehicle cable according to claim 1, characterized in that: The wrapping tape (7) is a PTFE microporous foam insulation tape with an overlap rate of more than 30%.

8. The bending-resistant vehicle cable according to claim 1, characterized in that: The sheath layer (8) is made of wear-resistant and oil-resistant chlorinated polyethylene, and its thickness is not less than 1.5 mm.

9. The bending-resistant vehicle cable according to claim 1, characterized in that: The conductor (1) consists of a pair of DC power core wires, a pair of signal control core wires, a pair of data transmission core wires and a protective grounding core wire, wherein the DC power core wires, the signal control core wires, the data transmission core wires and the protective grounding core wires are all made of multiple strands of finely twisted silver-plated copper wires.

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