High-temperature-resistant super-soft high-flexibility shielding cable for new energy automobile

Abstract

The utility model relates to the technical field of cables, in particular to a high-temperature-resistant super-soft high-flexibility shielding cable for a new energy automobile, which is sequentially provided with a wear-resistant outer sheath, a metal woven mesh layer I, a high-temperature-resistant inner sheath, an aluminum foil shielding layer II and three transmission wires from outside to inside. The three transmission wires abut against one another in an equilateral triangle shape, the inner side wall of the aluminum foil shielding layer abuts against the outer side walls of the transmission wires, gaps are formed between the inner wall of the aluminum foil shielding layer and the two adjacent transmission wires, and T-shaped flexible frameworks are arranged in the gaps. According to the utility model, the problems of poor bendability, insufficient high temperature resistance and poor shielding effect of the existing cable are solved, and the cable has the advantages of improved bendability, high temperature resistance, anti-electromagnetic interference capability and installation convenience.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to a high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles. Background Technology

[0002] In recent years, the rapid expansion of the new energy vehicle industry has greatly facilitated travel. Currently, the internal cables of new energy vehicles primarily use existing traditional cables to connect various internal components. However, due to the limited space within new energy vehicles, the bending performance of the cables is crucial. Existing cables are generally stiff and difficult to bend, leading to low efficiency during vehicle installation. Using more flexible cables fails to achieve the required flame retardancy and stable transmission characteristics. Furthermore, new energy vehicles require cables to withstand high-temperature environments during operation, but existing cables lack sufficient high-temperature resistance, easily leading to aging and damage, affecting vehicle safety and reliability. Simultaneously, the shielding performance of the cables is critical; existing cables have poor shielding, making them susceptible to external electromagnetic interference and affecting signal transmission quality. Therefore, improvements to existing technologies are urgently needed to address these issues. Utility Model Content

[0003] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles, comprising, from the outside to the inside, a wear-resistant outer sheath, a metal braided mesh layer, a high-temperature resistant inner sheath, an aluminum foil shielding layer, and transmission conductors. Three transmission conductors are arranged in an equilateral triangle shape, abutting against each other. The inner wall of the aluminum foil shielding layer abuts against the outer wall of the transmission conductors, and a gap is provided between the inner wall of the aluminum foil shielding layer and two adjacent transmission conductors. A T-shaped flexible skeleton is provided within the gap.

[0005] In some embodiments, the upper end face of the T-shaped flexible frame abuts against the inner wall of the aluminum foil shielding layer, and the lower left and right sides of the T-shaped flexible frame abut against the outer surfaces of the corresponding two transmission wires, respectively.

[0006] In some embodiments, all three transmission wires are multi-strand composite cores with an external insulating layer.

[0007] In some embodiments, the insulation layer on the outside of the three transmission wires is a different color.

[0008] In some embodiments, the T-shaped flexible skeleton is made of a flexible insulating material.

[0009] Compared with the prior art, the beneficial effects of this utility model are: by using the T-shaped flexible skeleton and the equilateral triangle arrangement of the transmission wires, combined with the multi-layer protection structure, the problems of poor bending performance, insufficient high temperature resistance and poor shielding effect of existing cables are solved, and the advantages of improved bending performance, high temperature resistance, anti-electromagnetic interference ability and convenient installation are achieved.

[0010] Details of one or more embodiments of this application are set forth in the following drawings and description to make other features, objects and advantages of this application more readily apparent. The embodiments of this application will provide a detailed description and understanding of the application. Attached Figure Description

[0011] Figure 1 This is a cross-sectional view of the present invention.

[0012] In the diagram: 1. Wear-resistant outer sheath; 2. Metal braided mesh layer one; 3. High-temperature resistant inner sheath; 4. Aluminum foil shielding layer two; 5. Transmission wire; 6. T-shaped flexible skeleton. Detailed Implementation

[0013] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0014] In traditional applications of internal cables in new energy vehicles, rigid wires suffer from low installation efficiency due to insufficient bending performance in confined spaces, while highly flexible wires cannot simultaneously meet the requirements of flame retardancy, stability, and signal transmission integrity. In high-voltage power transmission scenarios between new energy vehicle battery packs and drive motors, cables need to be routed through three right-angle bends within cable trays with a diameter of less than 50 mm. Traditional wires, due to their rigid cross-sectional structure, result in excessively large bending radii, making them unsuitable for installation space constraints, and repeated bending operations can easily cause insulation layer cracking. While using flexible wires can reduce bending resistance, the relative displacement of the wire core can easily lead to increased electromagnetic interference, and the insulation material softens and deforms under high-temperature conditions, affecting the flame retardancy rating.

[0015] For example, in the wiring scenario of the thermal management unit of an 800V high-voltage battery system, the cable needs to pass through a composite cavity structure containing seven sets of cooling pipes, with four continuous S-shaped bends inside the cavity. When the traditional three-core parallel cable passes through the second bend point, the core clustering effect causes longitudinal stress concentration in the outer sheath. After continuous operation at an ambient temperature of 150°C for 300 hours, the sheath material cracks. At this point, the core shielding layer lacks an effective support structure, and the spacing between adjacent conductors changes by more than 30% of the initial design, causing differential signal crosstalk. At the same time, the contact surface between the metal shielding layer and the core generates a triboelectric potential, leading to an increase in common-mode interference voltage.

[0016] If the above problems are not addressed, repeated bending during cable installation will accelerate material fatigue failure, shortening the cable assembly's lifespan to less than 60% of the design standard. Degraded electromagnetic compatibility performance will lead to increased false alarms in the battery management system, potentially triggering a protective power-off of the high-voltage system in severe cases. Localized overheating caused by conductor misalignment may cause the insulation material's thermal decomposition temperature to reach its peak prematurely, forming a breakdown path under extreme conditions, directly impacting the operational safety of the vehicle's high-voltage system.

[0017] Faced with the aforementioned problems, this application first analyzes the mechanical root causes of cable bending failure, finding that the traditional parallel arrangement of three cores leads to a clustering effect, causing uneven stress on the outer sheath and resulting in cracking. To address this, this application considers adjusting the core arrangement to achieve a more balanced stress distribution. Further analysis identifies the frictional potential problem at the contact surface between the shielding layer and the cores under high-temperature conditions, necessitating the introduction of a stable spacing structure between the conductors. Simultaneously, to balance flexibility and shielding effectiveness, an internal support system needs to be established without increasing overall rigidity. Through comparison of multiple solutions, a scheme combining geometrically symmetrical arrangement with a flexible frame balances stress dispersion and structural stability requirements.

[0018] In this regard, such as Figure 1 As shown, this application proposes a high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles. From the outside to the inside, the cable consists of a wear-resistant outer sheath 1, a metal braided mesh layer 2, a high-temperature resistant inner sheath 3, an aluminum foil shielding layer 4, and transmission conductors 5. There are three transmission conductors 5 arranged in an equilateral triangle shape, which abut against each other. The inner wall of the aluminum foil shielding layer abuts against the outer wall of the transmission conductors 5, and there is a gap between the inner wall of the aluminum foil shielding layer and two adjacent transmission conductors 5. A T-shaped flexible skeleton 6 is arranged in the gap.

[0019] The wear-resistant outer sheath 1 refers to the outermost protective structure wrapped around the cable. It can be made of insulating materials with waterproof, corrosion-resistant, and mechanical damage-resistant properties, protecting the internal structure from external environmental erosion and physical damage. The metal braided mesh layer 2 refers to a mesh shielding layer formed by woven metal wires, specifically made of copper or aluminum alloy, used to enhance the cable's electromagnetic shielding performance and anti-interference capabilities. The high-temperature resistant inner sheath 3 refers to a heat-resistant protective layer located inside the metal braided mesh layer, specifically made of high-temperature resistant insulating materials, used to isolate the effects of external high temperatures on the internal conductors. The aluminum foil shielding layer 4 refers to a shielding layer made of aluminum foil, specifically achieved by wrapping or winding aluminum foil, used to further block electromagnetic interference and improve signal transmission stability. The transmission conductors 5 are arranged in an equilateral triangle shape with close contact, meaning three conductors are arranged in an equilateral triangle and in close contact. This can be achieved using a multi-strand composite core structure, used to optimize spatial layout and improve the mechanical stability between the conductors. The T-shaped flexible frame 6 refers to a support structure with a T-shaped cross-section. It can be made of flexible insulating material to fill gaps and maintain the relative position between the conductor and the shielding layer, while allowing the cable to maintain structural integrity when it bends.

[0020] The core innovation of this application lies in the synergistic cooperation between three transmission conductors 5 arranged in an equilateral triangle and a T-shaped flexible frame 6, achieving high flexibility, stable shielding, and anti-interference capabilities within a limited space. The triangular layout optimizes the stress distribution between the conductors, while the T-shaped frame balances flexibility and structural stability, resolving the conflict between excessive rigidity or insufficient shielding in traditional cables.

[0021] The working process and principle of this application are as follows: the high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles is configured from the outside to the inside as follows: a wear-resistant outer sheath 1, a metal braided mesh layer 2, a high-temperature resistant inner sheath 3, an aluminum foil shielding layer 4, and transmission conductors 5. Three transmission conductors 5 are arranged in an equilateral triangle shape, abutting each other. The inner wall of the aluminum foil shielding layer abuts the outer wall of the transmission conductor 5, and a gap is provided between the inner wall of the aluminum foil shielding layer and the adjacent transmission conductor 5. A T-shaped flexible skeleton 6 is installed within the gap.

[0022] The wear-resistant outer sheath 1 provides mechanical protection, the metal braided mesh layer 2 provides electromagnetic shielding, the high-temperature resistant inner sheath 3 provides insulation and heat insulation, and the aluminum foil shielding layer 4 further enhances the electromagnetic shielding effect. Three transmission wires 5 are arranged in an equilateral triangle to ensure uniform stress distribution and improve flexibility. A T-shaped flexible frame 6 fills the gaps, maintains the wire spacing, and enhances structural stability.

[0023] The components work together to achieve functions such as high flexibility, high temperature resistance, and electromagnetic shielding. The equilateral triangle arrangement and T-shaped flexible frame are key technical features, which balance the requirements of flexibility and stability by optimizing the wire arrangement and support structure.

[0024] As a preferred embodiment, the solution of this application is implemented as follows: The high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles is configured from the outside in with the following layers: a wear-resistant outer sheath 1, a metal braided mesh layer 2, a high-temperature resistant inner sheath 3, an aluminum foil shielding layer 4, and a transmission conductor 5. The wear-resistant outer sheath 1 is made of polyvinyl chloride (PVC) material and has waterproof, corrosion-resistant, and mechanical damage-resistant functions. The metal braided mesh layer 2 is woven from tin-plated copper wire and provides electromagnetic shielding. The high-temperature resistant inner sheath 3 is made of silicone rubber material and has high thermal insulation efficiency. The aluminum foil shielding layer 4 is formed by winding aluminum foil, further enhancing the electromagnetic shielding effect.

[0025] Three transmission wires 5 are provided, each consisting of multi-strand composite wire cores with an external insulation layer. The three transmission wires 5 are arranged in an equilateral triangle shape, touching each other, and the external insulation layers are different colors for easy identification. The inner wall of the aluminum foil shielding layer 4 touches the outer wall of the transmission wire 5. A gap is provided between the inner wall of the aluminum foil shielding layer and two adjacent transmission wires 5, and a T-shaped flexible frame 6 is installed in the gap. The T-shaped flexible frame 6 is made of flexible insulating material, with its upper end touching the inner wall of the aluminum foil shielding layer, and its lower left and right sides touching the outer sides of the corresponding two transmission wires 5 respectively.

[0026] Through the above-described solution, this application improves the flexibility and bending performance of internal cables in new energy vehicles, solving the problem of low installation efficiency of traditional rigid cables in confined spaces. Simultaneously, the multi-layer shielding structure and T-shaped flexible frame 6 design ensure the electromagnetic shielding effect and structural stability of the cable under high flexibility conditions. Furthermore, the application of the high-temperature resistant inner sheath 3 and the wear-resistant outer sheath 1 improves the cable's heat resistance and mechanical strength, meeting the usage requirements of new energy vehicles under complex operating conditions.

[0027] In some of the solutions described above in this application, the T-shaped flexible frame 6 is set in the gap to support the structure between the transmission wire 5 and the aluminum foil shielding layer. However, when the cable is bent or vibrated, the contact stability between the flexible frame and the aluminum foil shielding layer and the transmission wire 5 is insufficient, which may lead to frame displacement or stress concentration, thereby affecting the integrity of the shielding layer and the transmission performance of the wire.

[0028] This application further proposes that the upper end face of the T-shaped flexible frame 6 abuts against the inner wall of the aluminum foil shielding layer, and the lower left and right sides of the T-shaped flexible frame 6 abut against the outer surfaces of the corresponding two transmission wires 5 respectively.

[0029] The upper surface of the T-shaped flexible frame 6 forms a surface contact with the inner wall of the aluminum foil shielding layer, while the lower left and right sides form point contacts with the outer surfaces of the two transmission wires 5, respectively. The flexible frame is made of flexible insulating material, with a T-shaped cross-section. The top width adapts to the curvature of the inner wall of the aluminum foil shielding layer, and the extended portions on both sides of the bottom abut against adjacent wires. For example, the top width of the frame is 1.5-2.5 mm, and the thickness of the bottom extension is 0.3-0.8 mm. The material used is silicone rubber or thermoplastic polyurethane elastomer. This structure creates a three-point support system in the axial direction, with the top support surface distributing the pressure of the shielding layer and the two side support points restricting the radial displacement of the wires.

[0030] Specifically, when the cable bends and deforms, the inner wall of the aluminum foil shielding layer applies pressure to the top of the T-shaped frame, while the extended portions on both sides simultaneously bear the reaction force from adjacent conductors. This three-point support structure creates mechanical balance, preventing the frame from deflecting within the gaps. The top contact area matches the curvature of the shielding layer, preventing the frame tip from piercing the aluminum foil layer; the bottom contact point is located at the maximum outer diameter of the conductor insulation layer, effectively limiting the mutual compression of the conductors. The flexible material allows the frame to undergo elastic deformation under load, returning to its original shape after the external force disappears, maintaining the gap structure while ensuring the cable's bending flexibility. This structure maintains a stable relative position between the shielding layer and the conductors under dynamic operating conditions, avoiding signal interference caused by poor contact.

[0031] As a preferred embodiment, the solution of this application is implemented as follows: The upper surface of the T-shaped flexible frame 6 abuts against the inner wall of the aluminum foil shielding layer, and the lower left and right sides of the T-shaped flexible frame 6 abut against the outer surfaces of the corresponding two transmission wires 5. Specifically, the T-shaped flexible frame 6 is made of a flexible insulating material, such as silicone rubber or thermoplastic elastomer. The upper surface of the T-shaped flexible frame 6 is tightly fitted to the inner wall of the aluminum foil shielding layer, and the lower left and right sides are in close contact with the outer surfaces of the two adjacent transmission wires 5. The cross-section of the T-shaped flexible frame 6 is T-shaped, with the transverse portion in contact with the inner wall of the aluminum foil shielding layer and the longitudinal portion inserted between the two transmission wires 5. Thus, the T-shaped flexible frame 6 can effectively fill the gap between the aluminum foil shielding layer and the transmission wires 5, improving the overall structural stability of the cable.

[0032] Through the above technical solution, the T-shaped flexible frame 6 of this application can effectively fill the gap between the aluminum foil shielding layer and the transmission conductor 5, improving the overall structural stability of the cable. Simultaneously, the flexible material properties of the T-shaped flexible frame 6 allow the cable to maintain good flexibility when bent, facilitating wiring installation in the confined space inside new energy vehicles. Furthermore, the T-shaped flexible frame 6 also acts as a buffer, reducing mutual friction between the transmission conductors 5 during use and extending the cable's service life.

[0033] In some of the solutions described above in this application, the transmission conductor 5 adopts a traditional single-strand core structure, which is prone to insulation layer damage due to stress concentration during frequent bending, affecting the reliability and service life of the cable.

[0034] This application further proposes that all transmission conductors 5 are multi-strand composite cores with an external insulation layer.

[0035] The multi-strand composite core is formed by twisting together multiple metal monofilaments, with the diameter of the metal monofilaments controlled within the range of 0.08-0.15 mm; the insulation layer is uniformly covered on the outer surface of the multi-strand composite core, with a thickness maintained at 0.3-0.5 mm; the ratio of the twisting pitch of the multi-strand composite core to the diameter of the monofilament is in the range of 8-12 times.

[0036] Specifically, the multi-strand composite core is formed through a stranding process. During stranding, gaps are created between the metal filaments, allowing the filaments to slide axially and distribute stress when the core is bent. The insulation layer is extruded over the core, using thermoplastic polyurethane, a material that maintains elasticity even at high temperatures. The ratio of the stranding pitch to the filament diameter is controlled within a specific range, ensuring core flexibility while preventing excessive filament displacement that could lead to a loose structure. When the multi-strand composite core is fitted with the T-shaped flexible skeleton 6, the core's flexibility allows it to deform freely within the skeleton's restraints, while the surface smoothness of the insulation layer is controlled to Ra≤3.2μm, reducing frictional losses at the contact surfaces with adjacent cores and the skeleton. The stranding direction of the core alternates between the S and Z directions to further balance the distribution of bending stress.

[0037] As a preferred embodiment, the solution of this application is implemented as follows: The transmission conductor 5 adopts a multi-strand composite core with an external insulation layer. Specifically, each transmission conductor 5 is made of multiple thin copper wires twisted together to form a multi-strand composite core structure. An insulating material, such as polyethylene or polyvinyl chloride, is wrapped around the core to form an insulation layer. This structure of the transmission conductor 5 has good flexibility and conductivity, while ensuring electrical insulation performance.

[0038] Through the above technical solution, this application improves the flexibility and bending performance of the cable, facilitating wiring and installation within the limited space of new energy vehicles. Simultaneously, the multi-strand composite core structure enhances the tensile strength and service life of the conductor. The outer insulation layer ensures electrical safety, preventing short circuits and leakage risks. This structure of the transmission conductor 5, while guaranteeing electrical performance, improves the overall flexibility and adaptability of the cable, effectively solving the problem of difficult operation of traditional rigid cables in the installation of new energy vehicles.

[0039] In some of the solutions described above in this application, an insulation layer is provided on the outside of the transmission wire 5, but it is difficult to quickly distinguish different wires during installation, resulting in reduced installation efficiency.

[0040] This application further proposes that the insulation layer on the outside of the transmission wire 5 has different colors.

[0041] The insulation layer uses different colored materials to wrap the multi-strand composite wire cores. Color differentiation is achieved by selecting three high-contrast colors: red, blue, and green. The different colored insulation layers correspond to the fixed positions of the wires within the triangular layout.

[0042] Specifically, the multi-strand composite wire core is wrapped with red, blue, or green insulation material, with each color corresponding to a wire at the vertex of a triangle. During installation, operators can quickly identify the connection port of each wire based on the color difference, avoiding manual identification errors. For example, the red-insulated wire corresponds to the positive power interface, blue to the negative interface, and green to the signal transmission interface. The color marking method works in conjunction with the physical arrangement of the transmission wires 5, reducing installation adjustment time within a limited space and improving assembly accuracy and efficiency.

[0043] As a preferred embodiment, the solution of this application is implemented as follows: the insulation layers on the outside of the transmission wires 5 are of different colors. For example, the insulation layer of the first transmission wire 5 is red, the insulation layer of the second transmission wire 5 is yellow, and the insulation layer of the third transmission wire 5 is blue. This color differentiation can be achieved by adding different colorants to the insulating material.

[0044] Through the above technical solution, this application can quickly identify different transmission conductors 5 during cable installation and maintenance, reducing the possibility of wiring errors and improving work efficiency. At the same time, the different colored insulation layers also help to more easily locate the problematic conductor when the cable is damaged, facilitating targeted repair and replacement.

[0045] In some of the solutions described above in this application, the T-shaped flexible frame 6 needs to simultaneously support the gap structure. However, insufficient material selection may lead to insufficient insulation performance or lack of flexibility, affecting the cable transmission stability and bending performance.

[0046] This application further proposes that the T-shaped flexible skeleton 6 is made of flexible insulating material.

[0047] The flexible insulating material can be at least one of silicone rubber, thermoplastic elastomer, or polyurethane. This material must meet insulation performance standards and also possess deformation recovery capability. Furthermore, the silicone rubber must be able to withstand an operating temperature range of -50°C to 200°C and have a volume resistivity greater than 1×10¹. 4 Ω·cm. During assembly, the flexible insulating material forms surface contact with the aluminum foil shielding layer through injection molding, and its elastic modulus is controlled within the range of 0.5-5MPa to ensure structural support.

[0048] Specifically, the T-shaped flexible skeleton 6, made of flexible insulating material, undergoes controllable elastic deformation when the cable is bent. The top of the skeleton maintains a contact area of ​​no less than 80% with the aluminum foil shielding layer, while the bottom surface in contact with the transmission conductor 5 experiences compressive deformation of no more than 10%. This material maintains a dielectric strength of no less than 20kV / mm at high temperatures, ensuring that no breakdown discharge occurs between adjacent transmission conductors 5. When the cable is subjected to radial pressure, the skeleton material absorbs mechanical stress through molecular chain slippage, preventing direct contact friction between the metal braided mesh layer and the transmission conductor 5.

[0049] As a preferred embodiment, the solution of this application is implemented as follows: The T-shaped flexible skeleton 6 is made of a flexible insulating material. Specifically, the T-shaped flexible skeleton 6 can be made of silicone rubber. Further, the silicone rubber material can be methyl vinyl silicone rubber. Thus, the T-shaped flexible skeleton 6 has good flexibility and insulation properties. For example, the T-shaped flexible skeleton 6 can maintain flexibility in a temperature range of -50℃ to 200℃, while having excellent electrical insulation properties.

[0050] Through the above technical solution, this application achieves an effective combination of flexibility and insulation performance in the T-shaped flexible skeleton 6. Therefore, the T-shaped flexible skeleton 6 can provide reliable insulation protection while maintaining cable flexibility. Furthermore, the flexibility of the T-shaped flexible skeleton 6 makes the cable easier to bend and install, improving overall vehicle installation efficiency. At the same time, the insulation performance of the T-shaped flexible skeleton 6 enhances the safety and reliability of the cable.

[0051] In some of the solutions described above in this application, the wear-resistant outer sheath 1 serves as the outermost structure of the cable and bears the protective function. However, existing materials may not be able to meet the requirements of waterproofing, corrosion resistance and mechanical damage resistance under complex working conditions, making the cable susceptible to environmental erosion or external force damage, affecting its service life and transmission stability.

[0052] This application further proposes that the wear-resistant outer sheath 1 is made of an insulating material that has the functions of waterproofing, corrosion resistance and mechanical damage resistance.

[0053] The material utilizes a multi-layer co-extrusion process to form a continuous and dense surface layer. Hydrophobic particles are embedded in the microstructure of this surface layer to block moisture penetration. Corrosion resistance is achieved by adding chemical corrosion resistant additives, such as incorporating fluorinated polymers into the substrate to resist acid and alkali corrosion. Resistance to mechanical damage is achieved by balancing the material's hardness and elastic modulus. A composite structure of thermoplastic elastomer and reinforcing fibers is employed, which disperses stress under pressure or friction, forming a self-healing microcrack buffer layer on the surface.

[0054] Specifically, when the cable is subjected to external mechanical impact, the reinforcing fibers in the material, through a three-dimensional mesh structure, evenly distribute localized stress to adjacent areas, preventing stress concentration that could lead to sheath rupture. The waterproof layer prevents liquid water from penetrating the internal metal layer through the lotus leaf effect formed by hydrophobic particles, while its dense structure isolates water vapor penetration. Anti-corrosion additives form a passivation film on the material surface, blocking the contact reaction between corrosive media and the substrate. For example, in salt spray testing, no oxidation spots appeared on the surface of the sheath material, and after 5000 continuous bending cycles, the surface crack propagation depth was controlled within 0.1 mm, verifying the reliability of its protective performance.

[0055] As a preferred embodiment, the solution of this application is implemented as follows: The wear-resistant outer sheath 1 is made of an insulating material that combines waterproof, corrosion-resistant, and mechanical damage-resistant functions. Specifically, the wear-resistant outer sheath 1 can be made of polyvinyl chloride (PVC). PVC material has excellent wear resistance, waterproofness, and corrosion resistance, which can effectively protect the internal structure of the cable from the influence of the external environment and mechanical damage. Furthermore, an appropriate amount of flame retardant can be added to the PVC material to improve its flame retardant performance and meet the safety requirements of new energy vehicles for cables.

[0056] Through the above technical solutions, this application improves the cable's abrasion resistance, water resistance, and corrosion resistance, extending its service life. As a result, the cable can maintain stable performance over a long period in the complex operating environment of new energy vehicles. Furthermore, the waterproof function of the abrasion-resistant outer sheath 1 effectively prevents moisture from penetrating the cable's interior, avoiding problems such as short circuits or decreased insulation performance caused by moisture. The anti-mechanical damage function protects the cable's internal structure from external impacts and friction, ensuring the cable's transmission performance and safety.

[0057] In some of the solutions described above in this application, the heat insulation efficiency of the high-temperature resistant inner sheath 3 is insufficient, and it cannot effectively block the heat conduction of the external high-temperature environment to the transmission wire 5, resulting in an increase in the internal temperature of the wire, which poses a risk of insulation layer aging and decreased signal transmission stability.

[0058] This application further proposes that the high-temperature resistant inner sheath 3 is made of an insulating material with high thermal insulation efficiency.

[0059] The high-temperature resistant inner sheath 3 is positioned between the metal braided mesh layer and the aluminum foil shielding layer, and is constructed from an insulating material with a high thermal resistance coefficient. Specifically, ceramicized silicone rubber can be used as the base material, with a thermal conductivity controlled within the range of 0.2-0.35 W / (m·K), or a multi-layer mica tape wrapping structure can be used to achieve layered insulation. The material selection must meet the requirements of a compressive strength of not less than 8 MPa and a long-term operating temperature maintained above 180℃.

[0060] Specifically, the inner sheath forms a thermal barrier through its low thermal conductivity, effectively slowing the transfer of external heat to the core area of ​​the conductor. When the metal braided mesh layer comes into contact with high-temperature components such as the engine compartment, the inner sheath can block approximately 65%-80% of radiant heat. Under dynamic bending conditions, the silicon-oxygen bond structure in the material's molecular chain maintains physical stability, preventing repeated deformation from causing a decrease in thermal insulation performance. The thermal resistance characteristics of the inner sheath and the electromagnetic shielding function of the aluminum foil shielding layer work synergistically to ensure that the multi-strand composite core maintains a stable insulation resistance value in high-temperature environments, ensuring that the fluctuation range of power transmission efficiency is controlled within ±2%.

[0061] As a preferred embodiment, the solution of this application is implemented as follows: the high-temperature resistant inner sheath 3 is made of an insulating material with high thermal insulation efficiency. Specifically, the high-temperature resistant inner sheath 3 can be made of polytetrafluoroethylene (PTFE). PTFE has excellent high-temperature resistance and insulation properties, and can maintain stable physical and chemical properties in high-temperature environments. Furthermore, the thickness of the high-temperature resistant inner sheath 3 can be set between 0.5 mm and 1.5 mm to ensure the thermal insulation effect without excessively increasing the overall diameter of the cable.

[0062] Through the above technical solutions, this application improves the high-temperature resistance of the cable. Therefore, the cable can maintain good insulation and mechanical properties in the high-temperature operating environment of new energy vehicles, avoiding insulation aging and damage caused by high temperatures. Furthermore, the use of the high-temperature resistant inner sheath 3 enhances the overall structural stability of the cable and extends its service life in high-temperature environments. Specifically, the high-temperature resistant inner sheath 3 effectively blocks external heat from being conducted inwards, protecting the internal transmission conductors 5 and the shielding layer, ensuring the normal operation of the cable in high-temperature environments.

[0063] In some of the above-mentioned solutions in this application, the wear-resistant outer sheath 1 is made of an insulating material that has the functions of waterproofing, corrosion resistance and mechanical damage resistance to protect the internal structure of the cable. However, in the process of selecting such materials, if the material thickness is insufficient, it cannot effectively resist mechanical damage, and if the thickness is too high, it will lead to a decrease in the overall flexibility of the cable.

[0064] This application further proposes that the thickness of the wear-resistant outer sheath 1 is 1.5 mm to 2.5 mm.

[0065] The thickness of the wear-resistant outer sheath 1 is controlled within a specific range to balance mechanical protection and cable flexibility requirements. This thickness range was experimentally verified to be: when the thickness is less than 1.5 mm, the outer sheath is prone to wear and cracking in vehicle vibration environments; when the thickness exceeds 2.5 mm, the cable bending radius increases, leading to limited installation space. The material adopts a multi-layer composite structure, with an inner tear-resistant fiber reinforcement layer and an outer wear-resistant particle coating.

[0066] Specifically, the outer sheath is formed using a three-layer co-extrusion process. The middle layer is a high-density polyethylene matrix, and the inner and outer layers are respectively composited with polyurethane elastomers. The matrix layer accounts for 60%-70% of the thickness, and the elastomer layers each account for 15%-20%. During vehicle operation, the middle layer provides structural support and distributes stress, while the elastomer layers absorb external impact energy. This structure, while maintaining a standard thickness of 2.0 mm, has been tested to withstand 200 Newtons of pressure with a bending radius less than 5 times the cable diameter.

[0067] As a preferred embodiment, the specific implementation of this application is as follows: The high-temperature resistant inner sheath 3 is extruded from polyimide material and wrapped around the outside of the aluminum foil shielding layer. This material can withstand continuous operation at 200°C for 240 hours without deformation. The sheath wall thickness is uniformly controlled within the range of 0.8-1.2 mm, and its cross-section has a concentric circular structure that closely fits the inner surface of the metal braided mesh layer 2. Specifically, the outer surface of the sheath is physically bonded to the metal braided mesh layer 2 through a hot-melt process, while the inner surface is formed with a micron-level rough surface through plasma treatment, so that the aluminum foil shielding layer 4 is firmly bonded to it through vacuum coating.

[0068] Through the above technical solution, this application effectively blocks the high temperature generated by the operation of the power battery pack from being conducted to the conductor, maintaining the stable resistivity of the transmission conductor 5. When wiring in confined spaces, the sheath material maintains structural integrity while allowing the cable to be bent with a radius less than 5 times the wire diameter. At the same time, through the stepped heat insulation design of three layers of materials, the measured core temperature is 28°C lower than that of traditional cables of the same specification, ensuring signal stability during high current transmission.

[0069] The above embodiments merely illustrate several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

[0070] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles, characterized in that: The structure consists of, from the outside in, a wear-resistant outer sheath, a metal braided mesh layer, a high-temperature resistant inner sheath, an aluminum foil shielding layer, and transmission wires. There are three transmission wires arranged in an equilateral triangle shape, which abut against each other. The inner wall of the aluminum foil shielding layer abuts against the outer wall of the transmission wires, and there is a gap between the inner wall of the aluminum foil shielding layer and two adjacent transmission wires. A T-shaped flexible skeleton is arranged in the gap.

2. The high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles according to claim 1, characterized in that: The upper surface of the T-shaped flexible frame abuts against the inner wall of the aluminum foil shielding layer, and the lower left and right sides of the T-shaped flexible frame abut against the outer surfaces of the corresponding two transmission wires.

3. The high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles according to claim 1, characterized in that: All three transmission wires are multi-strand composite cores with an external insulation layer.

4. The high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles according to claim 3, characterized in that: The insulation layers on the outside of the three transmission wires are all different colors.

5. The high-temperature resistant, ultra-soft, and highly flexible shielded cable for new energy vehicles according to claim 1, characterized in that: The T-shaped flexible skeleton is made of flexible insulating material.

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