Aluminum alloy flat cable for new energy automobile

Abstract

The utility model belongs to the field of cables, and provides an aluminum alloy flat cable for a new energy automobile, which comprises a flat rectangular cable formed by sequentially coating a plurality of conductors, an insulating layer, a composite shielding layer and a sheath layer from inside to outside, wherein every two adjacent conductors are arranged at equal intervals, and the conductors are coated with the insulating layers; the composite shielding layer comprises an extruded semi-conductive layer and a plurality of strands of aluminum alloy wire braided shielding layers, and the extruded semi-conductive layer and the insulating layer are extruded synchronously and are coated on the surface of the insulating layer to form an inner shielding layer of the conductor. Compared with the prior art, the composite shielding cable has the advantages that the composite shielding structure formed by weaving the extruded semi-conductive layer and the aluminum alloy wires is adopted, the light weight is realized, the electromagnetic interference suppression capability is enhanced, meanwhile, the flat design enables the layout of the cable to be more flexible and compact, and the space utilization rate is improved; and the heat dissipation capability is enhanced through a larger surface area, and the fault risk caused by overheating is reduced.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the cable field, concretely relates to a new energy automobile uses aluminum alloy flat cable. BACKGROUND

[0002] With the increasing global attention to environmental protection and sustainable development, the new energy vehicle (EV) market is experiencing unprecedented rapid growth. This trend not only drives the progress of battery technology and charging infrastructure, but also puts higher requirements on the internal components of electric vehicles, especially the cables used for power transmission and signal transmission.

[0003] Although traditional EV cables perform well in terms of electrical conductivity and shielding effect, they have some significant drawbacks:

[0004] (1) Heavy weight and high cost: Traditional EV cables usually use copper as the conductor material, although copper has excellent electrical conductivity, but its density is larger, resulting in the overall weight of the cable is heavier, which not only increases the overall weight of the vehicle, affects the vehicle's range, but also increases the manufacturing cost.

[0005] (2) Low space utilization: The traditional round cable design needs to occupy a larger space when arranged in the vehicle, especially in compact vehicles, the wiring difficulty is larger, this design not only limits the layout flexibility of other components in the vehicle, but also may affect the overall aesthetics and functionality of the vehicle.

[0006] (3) Insufficient heat dissipation: When the vehicle is under load, the sharp changes in voltage, current and frequency will cause the cable to generate a higher temperature instantaneously. Due to the small surface area of the round cable, the heat dissipation efficiency is low, which is prone to cause overheating problems, and further cause safety hazards. INVENTION CONTENTS

[0007] In view of the above shortcomings of the prior art, the technical problem to be solved by the utility model is to provide a new energy automobile aluminum alloy flat cable with light weight, improved space utilization and heat dissipation capacity.

[0008] The utility model solves the technical problems by adopting the following technical scheme: a new energy automobile aluminum alloy flat cable is provided, which includes a plurality of conductors, an insulation layer, a composite shielding layer and a sheath layer, and the cable is covered in a flat rectangular shape from the inside to the outside.

[0009] Among them, each adjacent two conductors are arranged at equal intervals and are covered by the insulation layer on the conductor.

[0010] The composite shielding layer comprises an extruded semiconductive layer and a plurality of aluminum alloy wire braided shielding layers, the extruded semiconductive layer is synchronously extruded with the insulating layer and is coated on the surface of the insulating layer to form an inner shielding layer of the conductor, and the plurality of aluminum alloy wire braided shielding layers are wound and coated on the extruded semiconductive layer to form an outer shielding layer of the conductor.

[0011] The sheath layer is coated on the outer shielding layer and is embedded in the braiding gap of the aluminum alloy wire braided shielding layer to stabilize the position of the aluminum alloy wire braided shielding layer.

[0012] In the above-mentioned aluminum alloy flat cable for new energy vehicles, each of the aluminum alloy conductors is formed by layering and tightly twisting a plurality of aluminum alloy wires with a diameter of 0.2 mm, and the twisting direction is leftward.

[0013] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the plurality of conductors are symmetrically distributed on the long side and the short side of the flat rectangular cable.

[0014] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the insulating layer and the sheath layer are made of high-temperature-resistant and high-tear-resistant silicone materials with a temperature resistance grade of 180 DEG C.

[0015] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the plurality of aluminum alloy wire braided shielding layers are single-layer and single-directionally wound and coated on the inner shielding layer.

[0016] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the braiding density of the aluminum alloy wire braided shielding layer is greater than 85%.

[0017] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the thickness of the extruded semiconductive shielding layer ranges from 0.2 mm to 0.4 mm.

[0018] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the plurality of conductors are distributed at equal intervals at the center position of the insulating layer.

[0019] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the plurality of conductors are arranged in a linear array along the long side direction of the cable.

[0020] In the above-mentioned aluminum alloy flat cable for new energy vehicles, the plurality of conductors are arranged in an array in the cable.

[0021] Compared with the prior art, the utility model has the beneficial effects that:

[0022] (1) The aluminum alloy flat cable for new energy vehicles of this utility model adopts a composite shielding structure of extruded semi-conductive layer + aluminum alloy wire braiding, which achieves lightweighting and enhances electromagnetic interference suppression capability. At the same time, the flat design makes the cable layout more flexible and compact, improves space utilization, and enhances heat dissipation capability through a larger surface area, reducing the risk of failure due to overheating.

[0023] (2) By using a double-layer co-extrusion process to simultaneously manufacture the extruded semi-conductive layer and the insulation layer, the wrapping process is reduced, effectively avoiding the formation of air gaps between the insulation layer and the shielding layer, preventing the cable from bulging after being heated, and eliminating quality problems caused by impurities entering the two-layer structure, thereby extending the service life.

[0024] (3) The insulation layer is made of high tear-resistant silicone material with a temperature resistance rating of 180℃, which improves electrical insulation performance, dielectric strength and low conductivity. It can effectively prevent leakage and short circuit in the high voltage environment inside the vehicle, and can maintain excellent stability in humid or temperature-varying environments. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of a flat rectangular cable.

[0026] In the diagram, 1 is the conductor; 2 is the insulating layer; 3 is the composite shielding layer; 30 is the extruded semiconductive layer; 31 is the aluminum alloy wire braided shielding layer; and 4 is the sheath layer. Detailed Implementation

[0027] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0028] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0029] Example 1:

[0030] like Figure 1 As shown, this utility model discloses an aluminum alloy flat cable for new energy vehicles, comprising a cable in the shape of a flat rectangle, consisting of a plurality of conductors 1, an insulation layer 2, a composite shielding layer 3, and a sheath layer 4, which are sequentially wrapped from the inside out.

[0031] Each two adjacent conductors 1 are arranged equidistantly and are covered by the insulation layer 2 on the conductor 1; the composite shielding layer 3 includes an extruded semi-conductive layer 30 and a number of aluminum alloy wire braided shielding layers 31, the extruded semi-conductive layer 30 is extruded synchronously with the insulation layer 2 and is covered on the surface of the insulation layer 2 to form the inner shielding layer of the conductor 1; the number of aluminum alloy wire braided shielding layers 31 are wound and covered on the extruded semi-conductive layer 30 to form the outer shielding layer of the conductor 1; the sheath layer 4 is covered on the outer shielding layer and is embedded in the braided gap of the aluminum alloy wire braided shielding layer 31 to stabilize the position of the aluminum alloy wire braided shielding layer 31.

[0032] Specifically, as shown in Figure 1 The cable in the first embodiment is different from the traditional circular cable structure, and the overall cable is designed in a flat rectangular structure. This design enables the cable to be arranged flexibly in a narrow space, improves the wiring efficiency and flexibility, reduces the layout restrictions of other components in the vehicle, and improves the overall aesthetics and functionality of the vehicle. At the same time, the larger surface area enhances the heat dissipation capacity, effectively reducing the risk of failure caused by overheating; preferably, the conductor 1 in the first embodiment is an aluminum alloy conductor 1, which not only maintains the electrical properties of pure aluminum, but also solves the problems of low elongation, tensile strength, and poor compression creep resistance and flexibility of pure aluminum conductor 1, thereby significantly improving the mechanical properties; Furthermore, by using aluminum alloy instead of traditional copper conductor 1, the overall weight of the cable is significantly reduced, and the lightweight design not only improves the vehicle's range, but also reduces manufacturing costs, enhancing the overall performance and economy of the vehicle; During the cable forming process, the first embodiment adopts a composite shielding structure of an extruded semi-conductive layer 30 and an aluminum alloy wire braided shielding layer 31, providing stronger electromagnetic interference suppression capability. This design not only enhances the shielding effect, but also improves the torsional performance of the cable, ensuring the stability and reliability of signal transmission and prolonging the service life of the flat rectangular cable.

[0033] Each aluminum alloy conductor 1 is formed by layering and tightly twisting a number of aluminum alloy wires with a diameter of 0.2 mm, and the twisting direction is left.

[0034] Further, as shown in Figure 1 During the cable forming process, high-purity aluminum alloy wires with a diameter of 0.2 mm are selected as the base material. These aluminum alloy wires have good electrical conductivity and mechanical properties, which can meet the strict requirements of new energy vehicle cables; a number of aluminum alloy wires with a diameter of 0.2 mm are layered and tightly twisted, and the number and arrangement of each layer of aluminum alloy wires can be adjusted according to specific requirements to ensure the optimal overall performance of the conductor 1; preferably, the twisting direction of the multiple aluminum alloy wires is left, which helps to improve the overall structural strength and flexibility of the conductor 1, thereby enhancing the bending resistance.

[0035] Furthermore, in this embodiment, the insulating layer 2 is made of a high tear-resistant silicone rubber material with a temperature resistance rating of 180℃, such as... Figure 1 As shown, the insulating layer 2 is a flat rectangle, which covers the outside of each aluminum alloy conductor 1 and the spacing between two adjacent aluminum alloy conductors 1. The material has the following advantages: (1) It has excellent electrical insulation performance, extremely high dielectric strength and low conductivity, which can effectively prevent leakage and short circuit in the high voltage environment of the vehicle; (2) It can remain stable in humid or temperature-varying environments; (3) It has high and low temperature resistance: it can be used for a long time in the temperature range of -60℃ to 250℃, maintaining good elasticity and insulation; (4) It has aging resistance and chemical corrosion resistance, excellent ozone resistance, oxidation resistance and weather aging resistance, and good tolerance to fuel oil and lubricating oil; (5) It has high flexibility and tear strength, with a tear strength of more than 30KN / m, which can effectively prevent mechanical damage; (6) It has physiological inertness and environmental protection, is non-toxic and odorless, and meets environmental protection requirements.

[0036] More preferably, similar to the insulating layer 2 described above, such as Figure 1 As shown, the high tear-resistant silicone rubber sheath layer 4 in this embodiment is a flat rectangle, covering the outside of the outer shielding layer and embedded in the braided gaps to stabilize the position of the shielding layer. The large surface area of ​​the flat rectangle allows it to better exchange heat with the surrounding environment, reducing the internal temperature of the cable and reducing the risk of failure due to overheating. This structure brings the following advantages: (1) It has high mechanical strength and wear resistance, which can effectively protect the internal structure of the cable from external mechanical damage such as vibration, friction, and compression inside the vehicle; (2) It has chemical corrosion resistance and oil resistance, and has good tolerance to various chemicals and oils; (3) It has good flexibility and elasticity, which facilitates bending and wiring in the narrow space inside the vehicle. It can still maintain good elasticity at low temperatures and will not become brittle or crack. At the same time, it will not soften or deform at high temperatures to adapt to extreme climates; (4) It has flame retardant properties, which meet the UL94V-0 flame retardant standard and can effectively prevent the spread of fire; It has weather resistance and aging resistance, and the cable can still maintain stable performance under long-term high load.

[0037] Further preferably, the extruded semiconductive layer 30 of the present embodiment is extruded synchronously with the insulation layer 2 and coated on the surface thereof by using a high-voltage cable double-layer co-extrusion process (which can be realized by an extruder), which significantly improves the production efficiency and product quality compared with the traditional extrusion insulation and then wrapping the aluminum plastic composite tape process. By reducing the wrapping process, not only is the air layer between the insulation layer 2 and the shielding layer avoided, preventing the cable from bulging after heating, but also the quality problems caused by impurities entering the two-layer structure are eliminated, thereby prolonging the service life of the cable. Preferably, the thickness of the semiconductive shielding layer in the present embodiment is in the range of 0.2mm-0.4mm, and is preferably controlled at about 0.3mm, without additional increase in the outer diameter and weight of the cable.

[0038] Further preferably, for the outer shielding layer, a number of aluminum alloy wires are woven into a structure and wrapped on the inner shielding layer by single-layer unidirectional winding to form a tight and uniform outer shielding layer. This weaving method can effectively cover the inner shielding layer (extruded semiconductive layer 30) and provide omnidirectional electromagnetic interference suppression capability. The weaving density needs to be strictly controlled during the weaving process, and the weaving density in the present embodiment is required to be more than 85%, which not only makes the structure lightweight, but also significantly improves the shielding effect and torsional performance of the shielding layer by using a higher weaving density.

[0039] Further preferably, the plurality of conductors 1 are symmetrically distributed on the long side and the short side of the flat rectangular cable in the present embodiment, and on this basis, the plurality of conductors 1 are distributed at the center position of the insulation layer 2 with equal spacing. This design significantly improves the space utilization of the cable, enabling the cable to be arranged flexibly in a narrow space, reducing the layout restrictions of other components in the vehicle, and improving the overall aesthetics and functionality of the vehicle. Moreover, the uniform distribution of the plurality of conductors 1 at the center position of the insulation layer 2 effectively avoids the relatively thin side being punctured due to uneven distribution of the conductors 1, ensuring the mechanical strength, and also ensuring the uniformity of heat dissipation and the convenience of production and manufacturing.

[0040] Further preferably, as shown in Figure 1 three aluminum alloy conductors 1 (three cores) are provided in the cable of the present embodiment, and of course, the number of aluminum alloys is not limited to this case in the present embodiment, and can be adaptively adjusted according to actual needs. Preferably, the three conductors 1 in the present embodiment are arranged in a linear array along the long side direction of the cable, which helps to uniformly distribute the current and magnetic field, simplifies the production process, and ensures the stability and reliability of signal transmission.

[0041] Embodiment Two:

[0042] The present embodiment two is changed on the basis of the structure of the above-mentioned embodiment one, and in addition to Figure 1In addition to the three conductors 1 arranged in a straight line, they can also be arranged in an array (e.g., two or three on each side, not shown in the figure) inside the cable. Without affecting the overall flexibility and normal use of the cable, the array arrangement of the conductors 1 can be adapted to the specifications and shape of the cable.

[0043] It should be noted that in this invention, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0044] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0045] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. An aluminum alloy flat cable for new energy vehicles, characterized in that, This includes cables that are flat and rectangular, consisting of several conductors, insulation layers, composite shielding layers, and sheathing layers wrapped sequentially from the inside out. The conductors are arranged at equal intervals between each pair of adjacent conductors and are covered by the insulating layer. The composite shielding layer includes an extruded semiconductive layer and a braided shielding layer of several strands of aluminum alloy wire. The extruded semiconductive layer is extruded simultaneously with the insulating layer and covers the surface of the insulating layer to form the inner shielding layer of the conductor. The braided shielding layer of several strands of aluminum alloy wire is wrapped around the extruded semiconductive layer to form the outer shielding layer of the conductor. The sheath layer covers the outer shielding layer and is embedded in the weave gaps of the aluminum alloy wire braided shielding layer to stabilize the position of the aluminum alloy wire braided shielding layer.

2. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, The conductor is an aluminum alloy conductor, and each aluminum alloy conductor is formed by layering and tightly twisting several aluminum alloy wires with a diameter of 0.2 mm in layers, with the twisting direction being to the left.

3. The aluminum alloy flat cable for new energy vehicles according to claim 1 or 2, characterized in that, Several of the conductors are symmetrically distributed on the long and short sides of the flat rectangular cable.

4. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, Both the insulation layer and the sheath layer are made of high tear-resistant silicone material with a temperature resistance rating of 180℃.

5. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, A single layer of aluminum alloy wire braided shielding is wrapped around the inner shielding layer in a single direction.

6. The aluminum alloy flat cable for new energy vehicles according to claim 5, characterized in that, The braiding density of the aluminum alloy wire braided shielding layer is above 85%.

7. The aluminum alloy flat cable for new energy vehicles according to claim 1, characterized in that, The thickness of the extruded semiconductive layer ranges from 0.2 mm to 0.4 mm.

8. The aluminum alloy flat cable for new energy vehicles according to claim 3, characterized in that, Several conductors are distributed at equal intervals at the center of the insulating layer.

9. The aluminum alloy flat cable for new energy vehicles according to claim 8, characterized in that, Several conductors are arranged in a line array along the long side of the cable within the cable.

10. The aluminum alloy flat cable for new energy vehicles according to claim 8, characterized in that, Several of the conductors are arranged in an array within the cable.

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