Flexible distortion-resistant power cable for new energy vehicle

Abstract

The utility model discloses a flexible distortion-resistant power cable for a new energy vehicle, which relates to the technical field of cables and comprises a cable conductor, the conductor is formed by twisting a plurality of strands of superfine silver-plated copper wires, an aramid fiber rope reinforced core is arranged in the conductor, the twisting pitch is optimized, and the twisting directions of adjacent twisting layers are opposite. And an insulating layer, a shielding layer, a filling layer and a sheath layer are sequentially wrapped outside. The insulating layer is a thermoplastic elastomer and nano ceramic particle composite material, and self-repairing microcapsule coatings are arranged on the inner and outer surfaces of the insulating layer; the shielding layer comprises an inner-layer tinned copper wire woven mesh, an outer-layer aluminum foil wrapping layer and conductive rubber; the filling layer is made of a flexible polyurethane foam material; the sheath layer is made of a fluororubber and polytetrafluoroethylene blended material, and the surface of the sheath layer is of a texture structure. Compared with the prior art, the beneficial effects are that the cable is good in flexibility, is resistant to distortion, is high in insulation and self-repairing capability, is excellent in electromagnetic shielding performance, can adapt to a complex environment, is convenient for wiring and space utilization, and is of great significance for the development of the new energy vehicle industry.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to a flexible, torsion-resistant power cable for new energy vehicles. Background Technology

[0002] Against the backdrop of a global push for sustainable development, new energy vehicles, as a crucial mode of transportation for reducing carbon emissions and decreasing reliance on traditional fossil fuels, are experiencing unprecedented development opportunities. The core systems of new energy vehicles heavily rely on power cables for stable power transmission, which places extremely stringent requirements on the performance of these cables.

[0003] The power systems and various electrical equipment in new energy vehicles are compactly arranged. During vehicle operation, the power cables constantly bend and twist due to vibrations, steering, acceleration, and deceleration. Traditional cables lack flexibility, and their internal conductors are prone to breakage during frequent bending and twisting, while the insulation layer is also easily damaged. This not only leads to a decline in the electrical performance of the cables and increased power transmission losses, but may also cause serious safety problems such as short circuits and leakage, threatening the safety of the vehicle and its passengers.

[0004] Furthermore, the limited interior space of new energy vehicles necessitates power cables with small bending radii to adapt to complex wiring environments. Traditional cables, due to structural design and material limitations, have larger bending radii, making them difficult to arrange flexibly within confined spaces. This not only affects the effective utilization of vehicle interior space but may also increase wiring costs and complexity. The operating environment of new energy vehicles is complex and variable. During daily operation, cables may come into contact with oil, moisture, acids, alkalis, and other chemicals, which can corrode the cable's insulation and sheath, reducing its performance and lifespan. Simultaneously, new energy vehicles face significant temperature variations when used in different regions and seasons. High temperatures may degrade cable insulation performance, while low temperatures can cause the cable to harden and become brittle, affecting its flexibility and torsion resistance. In addition, the numerous electrical devices inside vehicles create a complex electromagnetic environment, requiring cables with excellent electromagnetic interference resistance to ensure the stability and accuracy of power transmission. Therefore, developing a flexible, torsion-resistant power cable for new energy vehicles with excellent flexibility, torsion resistance, long-term stable operation in complex environments, and good electromagnetic compatibility is urgently needed and is of great significance for promoting the healthy development of the new energy vehicle industry. Utility Model Content

[0005] The purpose of this utility model is to provide a flexible, torsion-resistant power cable for new energy vehicles. It consists of conductors that transmit power, which are made of multiple strands of ultra-fine silver-plated copper wires twisted together, with an internal aramid fiber rope reinforcing core and adjacent stranded layers twisted in opposite directions. An insulation layer composed of thermoplastic elastomer and nano-ceramic particles with a self-healing microcapsule coating ensures insulation. A shielding layer containing tin-plated copper wire braided mesh, aluminum foil wrapping, and conductive rubber resists electromagnetic interference. All parts work together to ensure stable and efficient power transmission in complex environments.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] A flexible, torsion-resistant power cable for new energy vehicles includes a cable conductor. The cable conductor is characterized by being made of multiple strands of ultra-fine silver-plated copper wire, with the diameter of each wire controlled between 0.05-0.1 mm. Through a stranding process, an aramid fiber rope is placed inside the cable conductor as a reinforcing core, with the aramid fiber rope located at the center of the cable conductor. The stranding pitch of the cable conductor is optimized according to the conductor specifications. The cable conductor is sequentially wrapped with an insulation layer, a shielding layer, a filling layer, and a sheath layer.

[0008] The insulating layer is made of a thermoplastic elastomer and a nano-ceramic particle composite material, wherein the nano-ceramic particles are uniformly dispersed in the TPE matrix. The insulating layer is manufactured by a multi-layer co-extrusion process, and a self-healing microcapsule coating is provided on the inner and outer surfaces of the insulating layer, wherein the thickness of the microcapsule coating is between 0.05-0.1 mm.

[0009] The shielding layer includes an inner shielding layer and an outer shielding layer. The inner shielding layer is a tin-plated copper wire braided mesh with a braiding density of not less than 85%. The outer shielding layer is an aluminum foil wrapping layer with a thickness of 0.05-0.1 mm and a layer of conductive rubber coated on the outer surface of the aluminum foil.

[0010] The filling layer is placed in the gap between the cable cores and is made of flexible polyurethane foam material. The flexible polyurethane foam material is filled into the gap between the cable cores after foaming and curing.

[0011] The sheath layer is made of a blend of fluororubber and polytetrafluoroethylene, with a mass ratio of 7:3 between the fluororubber and polytetrafluoroethylene; the surface of the sheath layer has a textured structure.

[0012] When the multiple strands of ultra-fine silver-plated copper wire are twisted together, the twisting directions of adjacent stranded layers are opposite.

[0013] When this type of flexible, torsion-resistant power cable for new energy vehicles is in operation, the conductor formed by multiple strands of ultra-fine silver-plated copper wires with a diameter of 0.05-0.1mm is responsible for transmitting power. The aramid fiber rope in the center of the inner core enhances tensile strength, and the opposite twisting direction of adjacent stranded layers ensures structural stability. The thermoplastic elastomer and nano-ceramic particle composite material of the insulation layer provides reliable insulation, and the self-healing microcapsule coating automatically repairs itself when damaged. The tin-plated copper wire braided mesh in the shielding layer shields against low-frequency interference, while aluminum foil wrapping and conductive rubber shield against high-frequency interference. The flexible polyurethane foam filling layer reduces cable core friction, lowers noise, and provides support. The sheath layer, a blend of fluororubber and polytetrafluoroethylene, protects the cable with its excellent chemical corrosion resistance and abrasion resistance, and the surface texture structure prevents slippage and assists in heat dissipation. All parts work together to ensure that the cable transmits power stably and efficiently in the complex environment of new energy vehicles.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] The conductor is made of multiple strands of ultra-fine silver-plated copper wires twisted together, with adjacent strands twisted in opposite directions. This structural design makes the cable more flexible and better able to adapt to bending and twisting caused by vibration, steering, acceleration and deceleration during vehicle operation. It effectively avoids the problem that traditional cables are prone to breakage of the internal conductor during frequent bending and twisting due to poor flexibility.

[0016] An aramid fiber rope located at the center of the cable conductor serves as a reinforcing core, further enhancing the cable's tensile strength, ensuring the stability of the cable structure under complex working conditions, and improving its torsion resistance.

[0017] The insulation layer is made of thermoplastic elastomer and nano-ceramic particle composite material. The nano-ceramic particles are uniformly dispersed in the TPE matrix, which can provide reliable insulation effect and effectively reduce power transmission loss compared with traditional cables.

[0018] The inner and outer surfaces of the insulation layer are coated with self-healing microcapsule coatings. When the insulation layer is slightly damaged, the microcapsule coatings can automatically repair themselves, which greatly improves the service life and safety of the cable and reduces serious safety problems such as short circuits and leakage caused by insulation layer damage.

[0019] The shielding layer consists of an inner layer of tin-plated copper wire braided mesh and an outer layer of aluminum foil wrapping and conductive rubber. The inner tin-plated copper wire braided mesh effectively shields against low-frequency electromagnetic interference; the outer aluminum foil wrapping, coated with conductive rubber, provides even better shielding against high-frequency electromagnetic interference. This double-layer shielding structure ensures the stability and accuracy of power transmission even in the complex electromagnetic environment inside a vehicle.

[0020] The filling layer is made of flexible polyurethane foam material, which is filled into the gap between the cable cores after foaming and curing. This can reduce friction between the cable cores, reduce noise, and provide support for the cable, thereby enhancing the stability of the overall structure.

[0021] The sheath layer is made of a blend of fluororubber and polytetrafluoroethylene, which effectively resists corrosion from oil, moisture, acids, alkalis, and other chemicals, extending the cable's service life. The textured surface of the sheath layer not only prevents cable slippage but also aids in heat dissipation, enabling the cable to adapt to different temperature environments and meet the complex and varied operating environment requirements of new energy vehicles.

[0022] With its good flexibility and small bending radius, it can be flexibly arranged in the limited interior space of new energy vehicles, effectively improving the efficient use of vehicle interior space, while reducing wiring costs and difficulties, which is of great significance to promoting the healthy development of the new energy vehicle industry. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of this utility model;

[0024] In the diagram: 1. Cable conductor, 11. Aramid fiber rope, 2. Insulation layer, 21. Microcapsule coating, 3. Shielding layer, 31. Inner shielding layer, 32. Outer shielding layer, 33. Conductive rubber, 4. Filler layer, 5. Sheath layer. Detailed Implementation

[0025] The technical solutions of the present invention will now be described in detail with reference to the accompanying drawings of the embodiments.

[0026] like Figure 1 As shown, a flexible torsion-resistant power cable for new energy vehicles includes a cable conductor 1. The cable conductor 1 is characterized by being made of multiple strands of ultra-fine silver-plated copper wires twisted together, with the diameter of each wire controlled between 0.05-0.1 mm. Through a twisting process, an aramid fiber rope 11 is installed inside the cable conductor as a reinforcing core, with the aramid fiber rope 11 located at the center of the cable conductor 1. The twisting pitch of the cable conductor 1 is optimized according to the conductor specifications. The cable conductor 1 is sequentially wrapped with an insulation layer 2, a shielding layer 3, a filling layer 4, and a sheath layer 5.

[0027] The insulating layer 2 is made of a thermoplastic elastomer and a nano-ceramic particle composite material, wherein the nano-ceramic particles are uniformly dispersed in the TPE matrix. The insulating layer is manufactured by a multi-layer co-extrusion process. A self-healing microcapsule coating 21 is provided on the inner and outer surfaces of the insulating layer 2, respectively. The thickness of the microcapsule coating 21 is between 0.05-0.1 mm.

[0028] The shielding layer 3 includes an inner shielding layer 31 and an outer shielding layer 32. The inner shielding layer is a tin-plated copper wire braided mesh with a braiding density of not less than 85%. The outer shielding layer is an aluminum foil wrapping with a thickness of 0.05-0.1 mm, and a layer of conductive rubber 33 is coated on the outer surface of the aluminum foil.

[0029] The filling layer 4 is disposed in the gap between the cable cores and is made of flexible polyurethane foam material. The flexible polyurethane foam material is filled into the gap between the cable cores after foaming and curing.

[0030] The sheath layer 5 is made of a blend of fluororubber and polytetrafluoroethylene, with a mass ratio of fluororubber to polytetrafluoroethylene of 7:3; the surface of the sheath layer has a textured structure.

[0031] When the multiple strands of ultra-fine silver-plated copper wire are twisted together, the twisting directions of adjacent stranded layers are opposite.

[0032] The specific implementation method is as follows: First, the cable conductor 1 is fabricated using multiple strands of ultra-fine silver-plated copper wire with a diameter controlled between 0.05-0.1 mm. During the stranding process, an aramid fiber rope 11 is placed at the center of the cable conductor 1 as a reinforcing core. Simultaneously, the stranding pitch of the cable conductor 1 is optimized according to the conductor specifications, ensuring that the stranding directions of adjacent stranded layers are opposite during the stranding of the multiple strands of ultra-fine silver-plated copper wire. Next, the insulation layer 2 is fabricated using a thermoplastic elastomer and nano-ceramic particle composite material, manufactured through a multi-layer co-extrusion process, allowing the nano-ceramic particles to be uniformly dispersed in the TPE matrix. Then, a self-healing microcapsule coating 21 with a thickness of 0.05-0.1 mm is applied to the inner and outer surfaces of the insulation layer 2. The shielding layer 3 is fabricated in two parts: an inner shielding layer 31 and an outer shielding layer 32. The inner shielding layer uses a tin-plated copper wire braided mesh with a braiding density of not less than 85%, and the outer shielding layer uses aluminum foil with a thickness of 0.05-0.1 mm, with a layer of conductive rubber 33 coated on the outer surface of the aluminum foil. Filler layer 4 involves filling the gaps between the cable cores with flexible polyurethane foam material, which is then foamed and cured to fill the gaps. Finally, sheath layer 5 is fabricated using a blend of fluororubber and polytetrafluoroethylene in a 7:3 mass ratio, creating a textured structure on the surface of the sheath layer. This completes the fabrication of the flexible, torsion-resistant power cable for new energy vehicles.

Claims

1. A soft kink-resistant power cable for new energy vehicles, comprising a cable conductor (1), characterized in that, The cable conductor (1) is twisted by a plurality of superfine silver-plated copper wires, each of which has a diameter of 0.05-0.1 mm. A para-aramid fiber rope (11) is arranged inside the cable conductor as a reinforcing core, and the para-aramid fiber rope (11) is located at the center of the cable conductor (1). The twisting pitch of the cable conductor (1) is optimized according to the conductor specification. The cable conductor (1) is sequentially wrapped with an insulation layer (2), a shielding layer (3), a filling layer (4) and a sheath layer (5).

2. The soft, kink-resistant power cable for a new energy vehicle according to claim 1, characterized in that, The insulation layer is manufactured by a multi-layer co-extrusion process, and a microcapsule coating (21) with self-repairing function is arranged on the inner and outer surfaces of the insulation layer (2). The thickness of the microcapsule coating (21) is 0.05-0.1 mm.

3. The soft, kink-resistant power cable for a new energy vehicle of claim 1, wherein The shielding layer (3) includes an inner shielding layer (31) and an outer shielding layer (32). The inner shielding layer is a woven tin-plated copper wire mesh with a weaving density of not less than 85%. The outer shielding layer is an aluminum foil wrapping layer, and the thickness of the aluminum foil is 0.05-0.1 mm. A layer of conductive rubber (33) is coated on the outer surface of the aluminum foil.

4. The soft, kink-resistant power cable for a new energy vehicle of claim 1, wherein, The filling layer (4) is arranged at the gap between the cable cores and is made of flexible polyurethane foam material. The flexible polyurethane foam material is foamed and cured to fill the gap between the cable cores.

5. The soft, kink-resistant power cable for a new energy vehicle of claim 1, wherein When the plurality of superfine silver-plated copper wires are twisted, the twisting directions of adjacent twisted layers are opposite.

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