Copper conductor high-voltage energy storage wire harness
Through multi-layer protection mechanisms and modular quick-connect designs, the problems of heavy weight, low conductivity, and breakage of traditional high-voltage wire harnesses have been solved, achieving efficient connection and heat management of copper wires and improving the insulation and waterproof performance of the system.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-27
- Publication Date
- 2026-03-20
AI Technical Summary
Traditional high-voltage wiring harnesses use pure copper wires, which are heavy and costly. Aluminum alternatives have low conductivity and insufficient mechanical strength, making them prone to breakage, resulting in energy loss and heat generation, and affecting system efficiency.
It adopts a multi-layer protective structure design, including an inner core layer, an outer layer, an electromagnetic shielding layer, and an outer sheath. The inner core layer is made of multi-strand silver-plated copper wire, the outer layer is made of high thermal conductivity silicone, the electromagnetic shielding layer has a double-layer structure, the outer layer is made of flame-retardant TPE material, the insulation layer is made of aluminum foil wrapping + tin-plated copper wire braided mesh, and the modular quick-connect connector design prevents breakage.
It achieves efficient connection of copper wires, prevents breakage, quickly dissipates heat, enhances insulation and waterproof performance, and improves system efficiency.
Smart Images
Figure CN224021150U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model belongs to the technical field of energy storage wire harness, specifically relates to a copper wire high pressure energy storage wire harness. BACKGROUND
[0002] Generally adopt the copper wire of big cross section area, to bear high current, part scene uses the shell of silica gel or crosslinked polyethylene (XLPE) material, promotes the high temperature resistance and insulation performance.
[0003] Traditional high pressure wire harness adopts pure copper wire, although excellent conductivity exists the problems such as big weight, high cost. Part scheme attempts to replace copper material with aluminum material, but the conductivity of aluminum is low (only 61% of copper), and the mechanical strength is insufficient, which is easy to break due to fatigue in a vibrating environment, the wire resistance is large, which leads to energy loss and heating, and affects the system efficiency. UTILITY MODEL CONTENTS
[0004] The utility model discloses a copper wire high pressure energy storage wire harness to solve the problems in the background art. To achieve the above object, the utility model provides the following technical scheme: including wire and the modularization quick plug connector arranged at the both ends of wire;
[0005] The modularization quick plug connector includes a plug fixedly connected with the wire and a female seat matched with the plug.
[0006] The wire includes an inner core layer and a multilayer protection mechanism, both ends of the inner core layer are fixedly connected with a terminal, the terminal is fixed in the plug, and the end of the plug facing the wire is provided with a sealing cover.
[0007] It should be noted in the scheme that the multilayer protection mechanism includes an outer layer wrapped outside the inner core layer, and an electromagnetic shielding layer arranged outside the outer layer, and an insulating layer is further arranged between the outer layer and the electromagnetic shielding layer.
[0008] It should be noted in the scheme that the inner core layer is twisted by multiple strands of silver-plated copper wire.
[0009] It should be noted in the scheme that the electromagnetic shielding layer is further sleeved with an outer sheath.
[0010] It should be noted in the scheme that the female seat is provided with a female seat connector matched with the plug, the female seat connector is provided with a guide column, and the plug is provided with a guide groove matched with the guide column.
[0011] It should be noted in the scheme that the female seat is further provided with two mounting columns, and the mounting columns are symmetrically distributed on both sides of the female seat connector.
[0012] It should be noted in the scheme that a groove is formed in the outer wall of the plug, and a sealing ring is arranged in the groove.
[0013] It needs to be explained in the scheme that the female seat is provided with a plurality of glue filling grooves on the side away from the plug, and the glue filling grooves are located outside the female seat connector and the mounting column.
[0014] Compared with the prior art, the copper wire high-voltage energy storage wire harness provided by the utility model has at least the following beneficial effects:
[0015] (1) Through the setting of the modular quick plug, in actual use, the female seat is respectively installed on two power distribution devices required to be connected, and the plugs at both ends of the wire are respectively inserted into the female seats to connect the two power distribution devices, the terminal and the plug are both made of copper, can be well connected together, prevent breaking, and the plug and the female seat can be repeatedly plugged and unplugged.
[0016] (2) Through the setting of the multi-layer protection mechanism, the outer layer is a high-thermal-conductivity silica gel layer, heat is quickly conducted out, local temperature rise is reduced, the electromagnetic shielding layer is a double-layer structure, the inner layer is a high-temperature-resistant polyimide film, the outer layer is a flame-retardant TPE material, the insulation layer is an aluminum foil wrapping + tinned copper wire braided mesh, and the inner core layer adopts a plurality of silver-plated copper wires. BRIEF DESCRIPTION OF DRAWINGS
[0017] Fig. 1 is a schematic diagram of the three-dimensional structure of the utility model product;
[0018] Fig. 2 is a schematic diagram of the wire cross-section structure of the utility model product;
[0019] Fig. 3 is a schematic diagram of the female seat structure of the utility model product.
[0020] In the drawing: 1. wire; 2. plug; 3. sealing ring; 4. sealing cover; 6. terminal; 7. female seat; 8. mounting column; 9. female seat connector; 10. glue filling groove; inner core layer 101. inner core layer; outer layer 102. outer layer; insulation layer 103. insulation layer; electromagnetic shielding layer 104. electromagnetic shielding layer; outer sheath 105. outer sheath. DETAILED DESCRIPTION
[0021] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only a part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the utility model.
[0022] Please refer to Figs. 1-3The utility model provides a copper wire high -voltage energy storage wire harness, including wire 1 and the modularization quick connector of setting in wire 1 both ends, the modularization quick connector includes the plug 2 of fixed connection with wire 1 and the female seat 7 of adapting with plug 2, wire 1 includes inner core layer 101 and multilayer protection mechanism, both ends fixedly connected with terminal of inner core layer 101, terminal is fixed in plug 2, one end of plug 2 faces wire 1 and is equipped with sealing cover 4;
[0023] Through the setting of the modularization quick connector, in actual use, the female seat 7 is installed on two power distribution devices to be connected respectively, and the plug 2 at both ends of the wire 1 is inserted into the female seat 7 respectively to connect the two power distribution devices, the terminal and the plug 2 are both made of copper, which can be well connected together to prevent breakage, and the plug 2 and the female seat 7 can be repeatedly plugged and unplugged.
[0024] Further, referring to Figs. 1-3 It is worth noting that the multilayer protection mechanism includes an outer layer 102 wrapped outside the inner core layer 101, and an electromagnetic shielding layer 104 arranged outside the outer layer 102, and an insulating layer 103 arranged between the outer layer 102 and the electromagnetic shielding layer 104.
[0025] Through the setting of the multilayer protection mechanism, the outer layer 102 is a high-thermal-conductivity silicone layer that quickly conducts heat away to reduce local temperature rise, the electromagnetic shielding layer 104 has a double-layer structure, the inner layer is a high-temperature-resistant polyimide film (temperature resistance ≥ 200°C), the outer layer is a flame-retardant TPE material with a flame-retardant rating of UL94 V-0, and the insulating layer 103 is an aluminum foil wrapping + tinned copper wire braid mesh with a shielding efficiency of ≥ 90 dB, and the inner core layer 101 is composed of multiple strands of silver-plated copper wire.
[0026] Further, referring to Figs. 1-3 It is worth noting that the electromagnetic shielding layer 104 is further sleeved with an outer sheath 105.
[0027] Through the setting of the outer sheath 105, the outer sheath 105 is a wear-resistant nylon braided layer with an anti-UV coating on the surface to adapt to outdoor environments.
[0028] Further, referring to Figs. 1-3 It is worth noting that the female seat 7 is provided with a female seat connector 9 matched with the plug 2, the female seat connector 9 is provided with a guide column, and the plug 2 is provided with a guide groove matched with the guide column.
[0029] Through the setting of the female seat connector 9, when the plug 2 is inserted, the guide column in the female seat connector 9 and the guide groove on the plug 2 are matched to insert the plug 2 into the female seat connector 9.
[0030] Further, referring to Figs. 1-3As shown, it is worth mentioning that the female seat 7 is further provided with two mounting columns 8, which are symmetrically distributed on both sides of the female seat joint 9, a recess is formed in the outer wall of the plug 2, a sealing ring 3 is arranged in the recess, and a plurality of glue filling grooves 10 are arranged on the side of the female seat 7 away from the plug 2, and the glue filling grooves 10 are located outside the female seat joint 9 and the mounting columns 8;
[0031] Through the sealing ring 3 and the glue filling grooves 10, in actual use, the female seat 7 is mounted on the power distribution device through the mounting columns 8, waterproof glue is filled into the glue filling grooves 10 before mounting, and then the female seat 7 is mounted into the power distribution device, so that the waterproof performance between the female seat 7 and the power distribution device can be effectively enhanced, the sealing ring 3 is arranged in the recess on the outer wall of the plug 2, so that the waterproof performance between the plug 2 and the female seat joint 9 can be effectively enhanced, and the overall waterproof effect is achieved.
[0032] The copper wire high-voltage energy storage wire harness provided by the utility model is introduced, the principle and implementation mode of the utility model are described by applying the specific preferred embodiments in the introduction, these embodiments are only used for helping to understand the principle and core idea of the utility model, it should be pointed out that for ordinary skilled persons in the art, the implementation schemes in the above embodiments can be further combined or replaced without departing from the design idea of the utility model, the utility model can be improved and modified in several ways, and these improvements and modifications also fall within the protection scope of the utility model claim.
Claims
1. A copper conductor high-voltage energy storage harness, characterized in that: Includes a conductor (1) and modular quick-connect fittings at both ends of the conductor (1); The modular quick-connect connector includes a plug (2) fixedly connected to the wire (1) and a female socket (7) adapted to the plug (2); The conductor (1) includes an inner core layer (101) and a multi-layer protective mechanism. Terminals are fixedly connected to both ends of the inner core layer (101). The terminals are fixed inside the plug (2). A sealing cap (4) is provided on the end of the plug (2) facing the conductor (1).
2. The copper conductor high-voltage energy storage harness according to claim 1, characterized in that: The multi-layer protection mechanism includes an outer layer (102) wrapped around the inner core layer (101) and an electromagnetic shielding layer (104) disposed outside the outer layer (102). An insulating layer (103) is also provided between the outer layer (102) and the electromagnetic shielding layer (104).
3. The copper conductor high-voltage energy storage harness according to claim 2, characterized in that: The inner core layer (101) is made of multiple strands of silver-plated copper wire twisted together.
4. The copper conductor high-voltage energy storage harness according to claim 3, characterized in that: An outer sheath (105) is also provided outside the electromagnetic shielding layer (104).
5. The copper conductor high-voltage energy storage harness according to claim 4, characterized in that: The female connector (7) is provided with a female connector (9) that mates with the plug (2). The female connector (9) is provided with a guide post, and the plug (2) is provided with a guide groove that mates with the guide post.
6. The copper conductor high-voltage energy storage harness according to claim 5, characterized in that: The female connector (7) is also provided with two mounting posts (8), which are symmetrically distributed on both sides of the female connector (9).
7. The copper conductor high-voltage energy storage harness according to claim 6, characterized in that: A groove is provided on the outer wall of the plug (2), and a sealing ring (3) is provided in the groove.
8. The copper conductor high-voltage energy storage harness according to claim 7, characterized in that: The female connector (7) has several glue-filling grooves (10) on the side away from the plug (2), and the glue-filling grooves (10) are located on the outside of the female connector (9) and the mounting post (8).