High-performance lightweight high-voltage cable for new energy automobile

Abstract

The utility model discloses a high-performance light-weight high-voltage cable for a new energy automobile, which comprises a conductor layer, a cable cotton paper tape is wrapped outside the conductor layer, a first insulating layer, a second insulating layer and a third insulating layer are sequentially extruded outside the cable cotton paper tape, a first shielding layer and a second shielding layer are sequentially wrapped outside the third insulating layer, and the first shielding layer and the second shielding layer are sequentially wrapped outside the conductor layer. The second shielding layer is wrapped by a tensile buffer layer, and the tensile buffer layer is wrapped by an outer sheath in an extruded manner. The cable can bear high voltage and has the characteristics of light weight, oil resistance, acid and alkali resistance, high electromagnetic interference resistance, vibration impact resistance, halogen-free flame retardance and the like, and meanwhile, the cable is light in weight, so that the endurance is improved, and the installation difficulty of the cable is reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of power cable, concretely relates to a high performance light weight high voltage cable for new energy vehicle. BACKGROUND

[0002] With the enhancement of people's environmental protection consciousness and the progress of battery technology, and the introduction of various government incentive measures, the market size of new energy vehicles presents explosive growth. The electrical system of new energy vehicles needs high-performance cables to connect, therefore, the cable industry for new energy vehicles ushered in an unprecedented development opportunity, and the demand will continue to increase substantially. As new energy vehicles accelerate towards high voltage, intelligentization and long endurance, the electrical system puts forward higher requirements for the performance of the cable.

[0003] In order to adapt to the needs of high voltage platform and intelligent driving system, the cable for new energy vehicles should be able to withstand high voltage, have the characteristics of light weight, oil resistance, acid and alkali resistance, high anti-electromagnetic interference, anti-vibration impact and halogen-free flame retardant.

[0004] The existing high voltage cable still has deficiencies in comprehensive performance, and it is difficult to meet the stringent requirements of new generation vehicles, which are specifically manifested in the following aspects of core defects:

[0005] 1. Contradiction between light weight and conductivity is prominent

[0006] Traditional high voltage cables mostly use pure copper conductor or tin-plated copper conductor, which has excellent conductivity, but the weight per unit cross-sectional area is large (density about 8.9g / cm³), resulting in a high proportion of overall cable mass (3%-5% of the total vehicle mass), which seriously restricts the improvement of electric vehicle range; in addition, the tensile strength of pure copper conductor is limited (about 200-250MPa), and plastic deformation may occur under complex working conditions due to vibration or bending, which shortens the service life of the cable. Although the existing technology attempts to improve flexibility by reducing the diameter of copper wire (such as 0.2mm level), the too thin single wire may cause problems such as increased conductor resistance and intensified skin effect, which in turn reduces the efficiency of electric energy transmission.

[0007] 2. Insufficient environmental resistance: battery electrolyte (containing sulfuric acid and organic solvent) and salt spray environment easily erode traditional PVC / PE insulation layer, leading to insulation breakdown risk; existing materials (such as XLPE) are prone to softening and deformation under continuous high temperature (>120℃), and release toxic gases (such as hydrogen halide) when burning, which does not meet the stringent safety standards of EV battery compartment.

[0008] 3. Weak anti-interference ability: single-layer copper band shielding (shielding effectiveness <40dB) is insufficient to suppress high-frequency electromagnetic waves (such as charging pile harmonics and motor PWM signals), which may easily cause electronic system mis-triggering.

[0009] 4. Low impact resistance: Traditional polyester tape buffer layer (tensile strength <150MPa) is prone to breakage when subjected to vehicle vibration or collision, resulting in interlayer peeling or copper wire exposure; frequent bending or temperature cycling (-40℃~150℃) can easily cause insulation layer cracking, shortening cable life.

[0010] Therefore, it is necessary to develop a high-performance, lightweight high-voltage cable for new energy vehicles. Utility Model Content

[0011] In order to overcome the shortcomings of the existing technology, this utility model provides a high-performance lightweight high-voltage cable for new energy vehicles. The cable can withstand high voltage and has the characteristics of being lightweight, oil-resistant, acid and alkali-resistant, highly resistant to electromagnetic interference, vibration and shock resistant, and halogen-free flame retardant. At the same time, the lightweight cable not only helps to improve the driving range, but also reduces the difficulty of cable installation.

[0012] To achieve the above objectives, this utility model provides a high-performance, lightweight high-voltage cable for new energy vehicles, comprising a conductor layer, wherein the conductor layer is composed of a central strand and multiple strands wrapped around the central strand; each strand is made of silver-plated annealed round copper wire with a diameter of 0.15mm and a surface coated with a nano-graphene layer; the conductor layer is wrapped with cable cotton paper tape, and a first insulation layer, a second insulation layer and a third insulation layer are extruded on the cable cotton paper tape in sequence; a first shielding layer and a second shielding layer are wrapped on the third insulation layer in sequence; a tensile buffer layer is wrapped on the second shielding layer; and an outer sheath is extruded on the tensile buffer layer.

[0013] Furthermore, a temperature-sensing optical fiber is installed at the center of the central strand.

[0014] Furthermore, the thickness of the nano-graphene layer is 0.05 μm.

[0015] Furthermore, the first insulating layer is formed by extrusion of modified polyetheretherketone, with an extrusion thickness of 0.8~1.0 mm.

[0016] Furthermore, the second insulating layer is formed by extruding ceramicized silicone rubber with an extrusion thickness of 0.5~0.7mm.

[0017] Furthermore, the third insulation layer is extruded from halogen-free, low-smoke, flame-retardant, irradiated cross-linked polyolefin insulation material, with an extrusion thickness of 0.3~0.5mm.

[0018] Furthermore, the first shielding layer is made of aluminum-plastic composite tape with an aluminum layer thickness of 0.1mm, which is overlapped and wrapped with an overlap rate of 50%.

[0019] Furthermore, the second shielding layer is made of tin-plated copper wire loosely woven with a weaving density of 60%.

[0020] Further, the tensile-resistant buffer layer is formed by first weaving aramid fiber yarn into a grid-shaped tensile-resistant layer outside the second shielding layer, then injecting foamed polyethylene into the gaps between the grid of the tensile-resistant layer by extrusion and adhering the foamed polyethylene to the outer surface of the second shielding layer to form a continuous closed-cell foam cushion structure.

[0021] Further, the outer sheath is formed by extrusion of an environmentally friendly halogen-free flame-retardant TPU material, and a laser etching anti-slip pattern is formed on the surface of the outer sheath with an etching depth of 0.2 mm.

[0022] Compared with the prior art, the utility model has the advantages of:

[0023] 1. The conductor is a silver-plated annealed round copper wire bundle with a diameter of 0.15 mm coated with a nanometer graphene layer, which is twisted into a strand, and multiple strands are twisted together. This soft conductor structure can improve the flexibility of the cable. The thinner the single wire, the better the flexibility and the higher the tensile strength. Silver plating of the round copper wire can reduce the surface resistance of the conductor, effectively improve the conductivity of the conductor, and also enhance the oxidation resistance and corrosion resistance of the round copper wire. Coating graphene on the surface of the silver-plated round copper wire can further reduce the interface resistance of the copper wire, thereby improving the conductivity of the conductor, and also enhancing the tensile strength, wear resistance, and oxidation resistance of the round copper wire, and improving the heat dissipation performance of the conductor. The coating of graphene layer on the silver-plated round copper wire significantly improves the conductivity of the conductor. Conversely, under the same resistance working conditions, the effective cross-sectional area of the conductor can be reduced, which not only makes the cable lightweight and helps improve the endurance of the car, but also reduces the manufacturing cost.

[0024] 2. The built-in temperature measurement optical fiber in the conductor can monitor the working temperature of the cable in real time, prevent short circuit, overload and overheating, and ensure the safety of people and vehicles.

[0025] 3. The conductor is overlapped and wrapped with a cotton paper tape. Compared with traditional PP tape and polyester tape, the cotton paper tape has a light specific gravity, good toughness, and is non-toxic and environmentally friendly. It not only makes the conductor wrapping more compact, but also prevents the influence of conductor single wire burrs on the insulation layer, and has the function of oil absorption, improving the oil resistance of the cable.

[0026] 4. The insulation adopts a composite structure of a first insulation layer, a second insulation layer, and a third insulation layer. The first insulation layer is extruded with modified polyether ether ketone, which makes the cable have high mechanical strength, high temperature resistance, impact resistance, flame retardation, acid and alkali resistance, hydrolysis resistance, wear resistance, fatigue resistance, radiation resistance, and good electrical insulation performance, which can improve the temperature resistance of the cable to 200℃, the dielectric strength is ≥30kV / mm, and the high voltage resistance of the cable is improved. The second insulation layer is extruded with ceramicized silicone rubber, which makes the cable sintered into a ceramic body at a temperature above 600℃, realizing self-extinguishing and fire prevention in case of short circuit, and improving safety performance. The third insulation layer is extruded with halogen-free low-smoke flame-retardant radiation cross-linked polyolefin insulation material, which meets environmental protection requirements, has good high temperature resistance and aging resistance, excellent flame retardation, and further improves the safety of the line.

[0027] 5、Shielding layer adopts the combined structure of the first shielding layer and the second shielding layer, the first shielding layer adopts the aluminum plastic composite tape with the aluminum thickness of 0.1 mm to be overlapped and wrapped, instead of the traditional copper tape wrapping, so that the self weight of the cable is reduced, high-frequency electromagnetic interference can be reflected, and the electromagnetic interference resistance of the cable is improved; the second shielding layer adopts the sparse weaving (weaving density 60%) of the tinned copper wire, compared with the existing copper wire weaving structure, the weight and cost are reduced by 20% to 40%, and meanwhile, the shielding performance can be maintained; the combined structure of the shielding layer not only improves the electromagnetic interference resistance of the cable, but also meets the light weight requirement.

[0028] 6、The tensile buffer layer is formed by the following steps that the aramid fiber wire is woven into a grid-shaped tensile layer outside the second shielding layer, and then the foamed polyethylene is injected into the grid gap of the tensile layer by extrusion and is bonded with the outer surface of the second shielding layer, so that a continuous closed-cell foam buffer structure is formed; the structure design can resist the vibration impact of the vehicle; the buffer layer bears the tension and absorbs the stress peak value through compression deformation; the interlayer peeling strength is enhanced by the support of the aramid fiber; and the structure can remain stable in multiple temperature cycles (-40℃ to 150℃) and has high compression resilience.

[0029] 7、The outer sheath is extruded by the environment-friendly halogen-free flame-retardant TPU material; the pyrolysis recovery rate of the material is relatively high, and can usually reach more than 80%; meanwhile, the performance of halogen-free and low smoke is met, so that the green environmental protection policy requirement is effectively assisted; in terms of extreme environment adaptability, the oil resistance and acid and alkali resistance are excellent, so that the battery electrolyte leakage and salt mist corrosion can be effectively resisted; meanwhile, the anti-slip lines (depth 0.2 mm) are laser etched on the surface of the outer sheath; the texture structure can disperse local stress and relieve the damage of external force impact on the cable, so that the wear resistance is indirectly improved, and the vibration impact resistance of the cable to the vehicle is further improved. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 It is a structural schematic view of the utility model;

[0031] Figure 2 It is a structural schematic view of the silver-plated annealed round copper wire coated with a nano graphene layer of the utility model;

[0032] Figure 3 It is a structural schematic view of the tensile buffer layer of the utility model;

[0033] Figure 4 It is a structural schematic view of the outer sheath. DETAILED DESCRIPTION

[0034] The utility model is further illustrated below in combination with the drawings and specific embodiments, and it should be understood that these embodiments are only used for illustrating the utility model and not for limiting the scope of the utility model, and after reading the utility model, various equivalent modifications of the utility model made by those skilled in the art all fall within the scope defined by the claims attached to the utility model.

[0035] As shown in Figures 1-2 The utility model provides a kind of high-performance light-weight new energy vehicle with high voltage cable, including conductor layer 1, conductor layer outer wrapping cable cotton paper tape 3, compared with traditional PP band, polyester band, specific gravity is light, tenacity is good, nontoxic and environmental protection, not only can make conductor package more closely still can prevent conductor monofilament burr to the influence of insulating layer, simultaneously with the function of oil absorption, improve the oil resistance of cable;Cable cotton paper tape is extruded and packed first insulating layer 4, second insulating layer 5 and third insulating layer 6 in turn outside, form three-layer composite structure;Third insulating layer is covered in turn first shielding layer 7 and second shielding layer 8 outside, second shielding layer is covered tensile buffer layer 9 outside, tensile buffer layer is extruded and packed outer sheath 10 outside.

[0036] In the embodiment, conductor layer 1 is made of a strand 11 arranged at the center and a plurality of strands 11 surrounding the center; the soft conductor structure can improve the softness of the cable, the thinner the monofilament, the better the softness, and the higher the tensile strength; each strand 11 is twisted with a bundle of silver-plated annealed copper wires 13 with a diameter of 0.15 mm and a surface coated with a nanometer graphene layer 12; silver plating of the round copper wire can reduce the surface resistance of the conductor, effectively improve the conductivity of the conductor, and also enhance the oxidation resistance and corrosion resistance of the round copper wire; coating graphene on the surface of the silver-plated round copper wire can further reduce the copper wire interface resistance, thereby improving the conductivity of the conductor, and also enhancing the tensile strength, wear resistance and oxidation resistance of the round copper wire, and improving the heat dissipation performance of the conductor; coating the graphene layer on the silver-plated round copper wire significantly improves the conductivity of the conductor, and vice versa, under the same resistance working conditions, the effective cross-sectional area of the conductor can be reduced, which not only makes the cable lightweight to improve the endurance of the car, but also reduces the manufacturing cost.

[0037] In the embodiment, the center of the center strand is provided with a temperature measuring optical fiber 2, which can monitor the working temperature of the cable in real time, prevent short circuit, overload and overtemperature, and ensure the safety of people and vehicles.

[0038] In the embodiment, the thickness of the nanometer graphene layer is 0.05 um, which improves the conductivity of the conductor, and vice versa, under the same resistance working conditions, the effective cross-sectional area of the conductor can be reduced, which not only makes the cable lightweight to improve the endurance of the car, but also reduces the manufacturing cost.

[0039] In this embodiment, the first insulation layer is formed by extrusion of modified polyetheretherketone (PEEK) with an extrusion thickness of 0.8~1.0 mm. It has high mechanical strength, high temperature resistance, impact resistance, flame retardancy, acid and alkali resistance, hydrolysis resistance, wear resistance, fatigue resistance, radiation resistance, and good electrical insulation properties. It can improve the temperature resistance of the cable to 200℃, dielectric strength ≥30kV / mm, and improve the high voltage resistance of the cable.

[0040] In this embodiment, the second insulating layer is made of ceramicized silicone rubber extruded with an extrusion thickness of 0.5~0.7mm. It is sintered into a ceramic body at a high temperature above 600℃ to achieve self-extinguishing fire prevention in the event of a short circuit, thereby improving safety performance; it can resist corrosion from battery electrolyte and salt spray.

[0041] In this embodiment, the third insulation layer is made of halogen-free, low-smoke, flame-retardant, irradiated cross-linked polyolefin insulation material extruded with a thickness of 0.3~0.5mm. It meets environmental protection requirements, has good high temperature resistance and aging resistance, and excellent flame retardant and acid and alkali resistance, further improving the safety of the line.

[0042] In this embodiment, the first shielding layer is made of aluminum-plastic composite tape with an aluminum layer thickness of 0.1mm, with an overlap rate of 50%, which replaces the traditional copper tape wrapping, reduces the cable's weight, and can reflect high-frequency electromagnetic interference, thereby improving the cable's electromagnetic interference resistance.

[0043] In this embodiment, the second shielding layer is made of tin-plated copper wire with a loose braiding density of 60%. Compared with the existing copper wire braiding structure, the weight and cost are reduced by 20% to 40%, while maintaining high shielding performance. Together with the first shielding layer, it forms a double shielding structure. The combined structure of the shielding layers not only improves the electromagnetic resistance of the cable, but also meets the requirements of lightweighting.

[0044] In this embodiment, as Figure 3 As shown, the tensile buffer layer 9 is formed by first weaving a mesh-like tensile layer 91 with aramid fiber filaments outside the second shielding layer, and then injecting foamed polyethylene into the mesh gaps of the tensile layer through extrusion and bonding it to the outer surface of the second shielding layer to form a continuous closed-cell foam buffer structure layer 92. This structure design can resist the vibration and impact of vehicles. While bearing tensile force, the buffer layer absorbs stress peaks through compression deformation. With the support of aramid fiber, it enhances the interlayer peel strength. Moreover, this structure can remain stable in multiple temperature cycles (-40℃~150℃) and has a high compression rebound rate.

[0045] In this embodiment, the outer sheath is extruded from environmentally friendly halogen-free flame-retardant TPU material. This material has a high pyrolysis recovery rate, typically reaching over 80%, and simultaneously meets the requirements of halogen-free and low-smoke performance, effectively contributing to the requirements of green environmental protection policies. In terms of extreme environmental adaptability, it has excellent oil resistance and acid and alkali resistance, effectively resisting battery electrolyte leakage and salt spray corrosion.

[0046] In the embodiment, as shown in Figure 4 The surface of the outer sheath is provided with laser-etched anti-skid lines 101, the etching depth is 0.2mm, the texture structure can disperse local stress, relieve damage of external force impact on the cable, indirectly improve wear resistance and further improve the vibration impact resistance of the cable.

[0047] In summary, through the above design, the cable can withstand high voltage, has the characteristics of oil resistance, acid and alkali resistance, high electromagnetic interference resistance, vibration impact resistance and halogen-free flame retardant; through optimization of the conductor structure and material selection, the cable is lightened, the power endurance is improved, the cable installation difficulty is reduced, the harsh working condition environment is met, and the new energy vehicle high-voltage cable is improved in light weight, safety, environmental adaptability and intelligent monitoring.

[0048] The utility model has many specific application ways, the above-mentioned is only the preferred implementation mode of the utility model, it should be pointed out that, for ordinary skilled person in the art, on the premise of not departing from the principle of the utility model, can make a number of improvements, these improvements also should be regarded as the protection scope of the utility model.

Claims

1. A high-performance light-weight high-voltage cable for new energy vehicles, characterized in that: The cable comprises a conductor layer, which is formed by a central strand and a plurality of strands surrounding the central strand; each strand is twisted by a silver-plated annealed copper wire bundle with a diameter of 0.15 mm and a surface coated with a nano graphene layer; the conductor layer is surrounded by a cable cotton paper tape, the cable cotton paper tape is sequentially extruded by a first insulation layer, a second insulation layer and a third insulation layer, the third insulation layer is sequentially coated by a first shielding layer and a second shielding layer, the second shielding layer is coated by a tensile buffer layer, and the tensile buffer layer is extruded by an outer sheath. ​ 2. The high-performance lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The central strand is provided with a temperature measuring optical fiber.

3. The high-performance lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The thickness of the nano graphene layer is 0.05 um.

4. The high-performance lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The first insulation layer is extruded by modified polyether ether ketone, and the extrusion thickness is 0.8-1.0 mm.

5. The high-performance lightweight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The second insulation layer is extruded by ceramicized silicone rubber, and the extrusion thickness is 0.5-0.7 mm. 6.The high-performance light-weight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The third insulation layer is extruded by halogen-free low-smoke flame-retardant radiation crosslinked polyolefin insulation material, and the extrusion thickness is 0.3-0.5 mm. 7.The high-performance light-weight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The first shielding layer is overlapped and wrapped by an aluminum-plastic composite tape with an aluminum layer thickness of 0.1 mm, and the coverage rate is 50%. 8.The high-performance light-weight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The second shielding layer is woven by tinned copper wire with a weaving density of 60%. 9.The high-performance light-weight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The tensile buffer layer is formed by first weaving a tensile layer in a grid shape by aramid fiber outside the second shielding layer, then injecting foamed polyethylene into the grid gap of the tensile layer by extrusion and adhering to the outer surface of the second shielding layer, and forming a continuous closed-cell foam buffer structure. 10.The high-performance light-weight high-voltage cable for new energy vehicles according to claim 1, characterized in that: The outer sheath is extruded by an environmentally friendly halogen-free flame-retardant TPU material, and a laser etching anti-slip pattern is formed on the surface of the outer sheath with an etching depth of 0.2 mm.

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