Fire-resistant Ethernet cable for electric automobile

Abstract

The utility model relates to a fireproof Ethernet cable for an electric automobile. The fireproof Ethernet cable comprises an insulating cable core, a filling layer, a shielding layer, a fireproof layer and a sheath layer which are sequentially sleeved from inside to outside, the insulating wire core is formed by twisting two insulating wire cores. Each insulating wire core sequentially comprises a conductor and an insulating layer from inside to outside; the conductor is formed by twisting seven silver-plated copper-tin alloy wires, and the diameter of a single wire is 0.154 mm; the insulating layer is made of fluorinated ethylene propylene or soluble polytetrafluoroethylene; the filling layer is made of a flame-retardant TPE-S (thermoplastic elastomer-styrene) material with the hardness of 50-60D; the shielding layer comprises an inner layer made of double-sided aluminum plastic or copper plastic composite foil and an outer layer made of a tinned copper wire braid layer; the fireproof layer is formed by sequentially wrapping a layer of mica tape and a layer of glass fiber tape outside the shielding layer from inside to outside; and the sheath layer is made of ceramic silicone rubber. The utility model provides the fireproof Ethernet cable for the electric automobile, which has good fireproof performance and flame retardant performance.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of Ethernet cable, specifically refers to a kind of fireproof Ethernet cable for electric vehicle. BACKGROUND

[0002] With the acceleration of the trend of electrification, intelligentization, networking and sharing of automobiles, the annual output of electric vehicles is increasing year by year, and the proportion of newly manufactured electric household cars has broken through the 50% threshold. However, electric vehicle fire accidents also occur frequently, most of which are caused by battery thermal runaway, and the temperature can rise sharply to above 800℃. It is worth noting that the high-voltage cable, temperature sensing wire and Ethernet cable deployed around the battery currently generally use flame-retardant cable, rather than fire-resistant cable with higher safety standards. In particular, the temperature resistance level of Ethernet cable is usually only 105℃. Once the battery catches fire, these cables are prone to fail in the fire, causing high-voltage cable electrical breakdown, communication line short circuit, and further exacerbating the spread of fire, triggering the out-of-control access control system and other chain reactions, which seriously hinders the emergency evacuation of passengers.

[0003] In view of this, some research has proposed a solution of using fire-resistant high-voltage cable around the battery, and a feasible cable structure has been designed. In contrast, the discussion on fire-resistant vehicle Ethernet cable is relatively scarce.

[0004] The insulation layer of the vehicle-mounted Ethernet cable of the prior art is mostly made of modified polypropylene material, and the sheath is generally made of 105℃ grade flame-retardant material. However, under the condition of battery combustion, such cable will burn quickly and cannot maintain the necessary working time, thereby causing the access control system to fail to open in time and seriously delaying the escape opportunity of passengers.

[0005] Currently, ternary lithium battery used in vehicles can only take 5 seconds from thermal runaway to open flame, and then the fire spreads rapidly within 30 seconds, with a flame temperature of 800℃-1000℃, forming a large area of burning with dense black smoke. The fire usually covers the entire vehicle within 2 minutes, which is a very serious situation. According to the authoritative data of the State Fire Administration, the escape opportunity after the appearance of open flame is extremely limited, only within the first 1 minute. Therefore, it is crucial to ensure that the Ethernet cable can work normally during this life-and-death period to facilitate the smooth evacuation of passengers. For high-frequency vehicle Ethernet cable with a speed of gigabit or above, its high-frequency transmission characteristics require very high requirements for insulation materials and processing precision. Unfortunately, many fire-resistant materials cannot be used as insulation due to their inability to meet these stringent conditions. Therefore, when designing fire-resistant vehicle Ethernet cable, new paths and methods must be explored to ensure the reliability and safety of the cable under extreme conditions. SUMMARY

[0006] The technical problem to be solved by this utility model is to provide a fire-resistant Ethernet cable for electric vehicles with good fire resistance and flame retardant properties.

[0007] This utility model is implemented as follows:

[0008] A fire-resistant Ethernet cable for electric vehicles includes: an insulated core, a filling layer, a shielding layer, a fireproof layer, and a sheath layer, which are sequentially arranged from the inside out.

[0009] The insulated wire core is made of two strands; each insulated wire core includes, from the inside out: a conductor and an insulation layer; the conductor is made of 7 silver-plated copper-tin alloy wires stranded together, with a single wire diameter of 0.154 mm; the insulation layer is made of perfluoroethylene propylene or soluble polytetrafluoroethylene.

[0010] The filler layer uses a flame-retardant TPE-S material with a hardness of 50-60D;

[0011] The shielding layer includes: an inner layer made of double-sided aluminum-plastic or copper-plastic composite foil, and an outer layer of tin-plated copper wire braided layer;

[0012] The fireproof layer is formed by wrapping a layer of mica tape and a layer of glass fiber tape around the outside of the shielding layer from the inside out.

[0013] The sheath layer is made of ceramicized silicone rubber.

[0014] Furthermore, the insulating layer is made of FEP foam.

[0015] Furthermore, the thickness of the mica strip is 0.1 mm.

[0016] Furthermore, the diameter of the tin-plated copper wire in the shielding layer is 0.1 mm.

[0017] The advantages of this invention are as follows: The insulation layer has been upgraded to use a fluoroplastic material with a higher temperature resistance rating. Simultaneously, a TPE-S flame-retardant filler layer, a mica tape with poor thermal conductivity, and a fiberglass tape are sequentially wrapped around the outside of the cable, forming an effective heat insulation barrier for the insulation layer. Furthermore, the sheath layer has been upgraded to ceramicized silicone rubber capable of withstanding higher temperatures, further improving the cable's high-temperature resistance. When the cable encounters a high-temperature flame, thanks to the dual heat insulation effect of the flame-retardant sheath layer and the fireproof layer, the failure time of the insulation layer can be significantly delayed, ensuring that the Ethernet cable can maintain normal operation for one minute after an open flame occurs. In a flame combustion environment reaching 1000℃, this Ethernet cable can continue to operate normally for more than 100 seconds, demonstrating excellent fire resistance. In addition, this Ethernet cable also has excellent flame-retardant properties, effectively delaying the spread of fire even after it has started, providing sufficient escape time for occupants and ensuring their safety. Attached Figure Description

[0018] The present invention will now be further described with reference to the accompanying drawings and embodiments.

[0019] Figure 1 This is a schematic diagram of the structure of this utility model. Attached image description:

[0021] 1-Insulated core, 101-Conductor, 102-Insulation layer, 2-Filling layer, 3-Shielding layer, 301-Inner layer of double-sided aluminum-plastic or copper-plastic composite foil, 302-Outer layer of tin-plated copper wire braided layer, 4-Fireproof layer, 401-Mica tape, 402-Glass fiber tape, 5-Sheath layer. Detailed Implementation

[0022] like Figure 1 As shown, a fire-resistant Ethernet cable for electric vehicles includes: an insulated core 1, a filling layer 2, a shielding layer 3, a fireproof layer 4, and a sheath layer 5, which are sequentially arranged from the inside out.

[0023] The insulated core 1 is made of two strands twisted together; each insulated core 1, from the inside out, includes: conductor 101 and insulation layer 102.

[0024] Conductor 101 is made of seven silver-plated hard copper-tin alloy wires twisted together, with a tensile strength of over 700 MPa. The diameter of a single wire is 0.154 mm, and the tin content in the copper-tin alloy is 0.3%. The use of silver-plated copper alloy conductors not only maintains the tensile strength and electrical performance of existing Ethernet cables, but also achieves miniaturization, making the entire cable more compact and lightweight.

[0025] Insulation layer 102 uses perfluoroethylene propylene (FEP) or soluble polytetrafluoroethylene (PFA) as solid insulation material. For applications with high time delay requirements, FEP foam can also be used. Compared with modified polypropylene, fluoroplastic materials have a higher temperature resistance rating (FEP short-term temperature resistance 260℃~300℃, long-term operating temperature 200℃; PFA short-term temperature resistance 250℃~280℃, long-term operating temperature 250℃), thereby enhancing the fire resistance of the cable.

[0026] Filler layer 2 uses flame-retardant TPE-S material with a hardness of 50-60D. The filler layer is extruded using a low-pressure extrusion method, with the addition of a suitable release agent (such as PTFE powder, which is sprayed in small amounts during cable production and adsorbed onto the TPE-S, making it barely visible to the naked eye in the finished product). This achieves non-adhesion between the filler layer and the wire pair insulation layer, leaving a small gap. This design allows the insulated core and filler layer to slide relative to each other when the wire is bent, reducing damage to the wire pair structure caused by bending. Simultaneously, the cylindrical outer contour of filler layer 2 helps form a cylindrical cavity on the inner surface of the shielding layer, optimizing the cable's return loss and unbalanced attenuation indicators. Furthermore, the TPE-S material provides excellent tensile, compressive, and thermal insulation properties, protecting the wire pair. Its excellent anti-aging properties allow it to maintain high shape and physical properties during long-term use, with minimal adverse impact on the wire pair's transmission performance.

[0027] The shielding layer 3 includes an inner layer 301 made of double-sided aluminum-plastic or copper-plastic composite foil, and an outer layer 302 made of tin-plated copper wire braid with a diameter of 0.1 mm; the braiding density of the braiding layer is not less than 85%, which further enhances the shielding effect and mechanical strength of the cable.

[0028] Fire-resistant layer 4 consists of a mica tape 401 and a fiberglass tape 402, each approximately 0.1 mm thick, wrapped sequentially around the shielding layer 3. The mica tape possesses excellent high-temperature insulation properties, while the fiberglass tape serves as a reinforcing support layer, maintaining mechanical strength at high temperatures and preventing the mica layer from detaching. By selecting different fire-resistant layer thicknesses and mica types, the cable's flame resistance temperature and burning time can be further optimized, improving its fire resistance and providing ample escape time for occupants of new energy electric vehicles.

[0029] Finally, a layer of ceramicized silicone rubber is extruded over the fireproof layer 4 as a sheath layer 5, which provides additional fire resistance and flame retardancy.

[0030] Given that conventional fire-resistant materials are difficult to apply directly to the insulation layer of Ethernet cables, this invention proposes a solution from another perspective: based on the existing flame-retardant Ethernet cable structure, the insulation layer is upgraded to use a fluoroplastic material with a higher temperature resistance rating. Simultaneously, a TPE-S flame-retardant filler layer, mica tape with poor thermal conductivity, and fiberglass tape are sequentially wrapped around the cable, forming an effective heat insulation barrier for the insulation layer. Furthermore, the sheath layer has been upgraded to ceramicized silicone rubber capable of withstanding higher temperatures, further improving the cable's high-temperature resistance. When the cable encounters a high-temperature flame, thanks to the dual heat insulation effect of the flame-retardant sheath layer and the fireproof layer, the failure time of the insulation layer can be significantly delayed, ensuring that the Ethernet cable can maintain normal operation for one minute after an open flame occurs. Although this performance requirement is relatively lenient compared to traditional fire-resistant cables, it is sufficient to meet the communication needs inside vehicles in emergency situations, providing strong support for rescue operations.

[0031] This utility model discloses a fire-resistant Ethernet cable for electric vehicles. While fully retaining the excellent high-frequency transmission performance of existing Ethernet cables, it achieves a significant improvement in fire resistance. In a flame environment reaching 1000℃, this Ethernet cable can continue to operate normally for more than 100 seconds, demonstrating excellent fire resistance. Furthermore, this cable also possesses excellent flame-retardant properties, effectively slowing the spread of fire even after it has already started, providing ample escape time for occupants and ensuring their safety.

[0032] The above embodiments and figures are not intended to limit the product form and style of this utility model. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of this utility model.

Claims

1. A fire resistant Ethernet cable for electric vehicles, characterized by: The utility model relates to a kind of fireproof cable, including: Insulated wire core, filling layer, shielding layer, fireproof layer, sheath layer are sequentially sleeved from inside to outside; The insulated wire core adopts two strands;Each insulated wire core includes conductor and insulation layer from inside to outside;The conductor adopts seven silver-plated copper-tin alloy wires and is stranded, and the diameter of single wire is 0.154mm;The insulation layer adopts polytetrafluoroethylene or soluble polytetrafluoroethylene; The filling layer uses the flame-retardant TPE-S material with hardness of 50-60D; The shielding layer includes inner layer of double-sided aluminum plastic or copper plastic composite foil and outer layer of tinned copper wire braiding layer; The fireproof layer is a mica tape and glass fiber tape wrapped around the shielding layer from inside to outside; The sheath layer adopts ceramicized silicone rubber.

2. A fire resistant Ethernet cable for electric vehicles as claimed in claim 1, wherein: The insulation layer adopts FEP foaming type.

3. The fire resistant Ethernet cable for electric vehicles of claim 1, wherein: The thickness of the mica tape is 0.1mm.

4. The fire resistant Ethernet cable for electric vehicles of claim 1, wherein: The diameter of the tinned copper wire in the shielding layer is 0.1mm.

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