High-thermal-conductivity silicone rubber insulation new energy automobile high-voltage cable

Abstract

The utility model discloses a high-thermal-conductivity silicone rubber insulation high-voltage cable for a new energy automobile, and the cable consists of a soft copper conductor, a semi-conductive wrapping layer, a silicone rubber insulation layer, a non-metal shielding layer, a metal braided shielding layer, and a sheath layer. A high-thermal-conductivity silicone rubber insulating layer and a non-metal shielding layer are uniformly extruded on the semi-conductive wrapping layer, tinned copper wires are braided outside the non-metal shielding layer to form a metal braided shielding layer, the non-metal shielding layer and the metal braided shielding layer form a composite shielding structure layer, and a high-thermal-conductivity silicone rubber sheath layer is extruded outside the metal braided shielding layer. The cable has the advantages that the cable is high in heat conduction, good in insulation resistance, soft and good in electromagnetic shielding, the rated voltage is DC 1500V and below, the heat conduction coefficient of the insulation and sheath is 3.0-3.8 W / m.K, the flame retardant property of the cable can reach V-0 (UL94), the temperature rise test of the cable is reduced by 10-20K, and the problem of temperature rise on the surface of the cable is effectively solved.

Description

Technical Field

[0001] This utility model relates to a cable, specifically a high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles with a rated voltage of DC 1500V and below. Background Technology

[0002] With the rapid development of the new energy electric vehicle sector, electric vehicles will gradually replace gasoline-powered vehicles. However, the architecture of electric vehicle systems differs significantly from that of traditional gasoline-powered vehicles. For example, the high-voltage cable system in electric vehicles, which connects components such as high-voltage batteries, inverters, and motors, imposes various technical requirements. Because the internal cables of electric vehicles connect components like batteries, inverters, and motors, the high-voltage cables need to transmit higher currents. Depending on the power requirements of the system components, the current can reach 250A to 500A, or even higher. This high current transmission results in high power consumption and component heating, therefore the high-voltage cables must be designed to withstand a wider temperature range. In contrast, conventional gasoline-powered vehicles typically use cables with a rated temperature limit of 105°C, unless the cables are used in the engine compartment or other areas requiring higher temperatures. Electric vehicle high-voltage cables typically exceed the temperature limits for general gasoline-powered vehicles, reaching 125°C or 150°C. If other influencing factors exist in the loops within an electric vehicle, OEMs may impose even higher temperature resistance requirements, such as near the exhaust pipe, in front of the motor, or on the back of the battery.

[0003] Invention patent application number 202210543632.7 describes a high-voltage thermally conductive cable for new energy vehicles and its manufacturing process. The insulation material is modified with polydopamine, which improves its thermal conductivity but reduces its insulation performance. The sheath layer is made of chlorosulfonated polyethylene rubber, which can only withstand temperatures up to 125°C over a long period of time. The sheath contains halogens, which are flammable and produce smoke and toxicity.

[0004] Currently, common insulation materials for high-voltage cables inside new energy vehicles include XLPO, TPE, and silicone rubber. These materials have low thermal conductivity, resulting in poor cable heat dissipation. Finding or developing a high-temperature resistant, environmentally friendly, low-smoke, halogen-free, flame-retardant, and fast-heat-dissipating high-voltage cable for new energy vehicles has become a problem that the industry needs to solve. Utility Model Content

[0005] This utility model provides a high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles with a rated voltage of DC 1500V and below.

[0006] To achieve the above objectives, the technical solution of this utility model is as follows:

[0007] A high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles is composed of a soft copper conductor, a semi-conductive wrapping layer, a silicone rubber insulation layer, a non-metallic shielding layer, a metal braided shielding layer, and a sheath layer. The semi-conductive wrapping layer is formed by wrapping a semi-conductive shielding tape around the soft copper conductor. The high thermal conductivity silicone rubber insulation layer and the non-metallic shielding layer are uniformly extruded on the semi-conductive wrapping layer. Tin-plated copper wires are braided outside the non-metallic shielding layer to form a metal braided shielding layer. The non-metallic shielding layer and the metal braided shielding layer constitute a composite shielding structure layer. The high thermal conductivity silicone rubber sheath layer is extruded outside the metal braided shielding layer.

[0008] The soft copper conductor conforms to the performance of the sixth type of soft copper conductor in GB / T 3956-2008, which is a single bare copper wire or a tin-plated copper wire.

[0009] The semi-conductive shielding tape of the semi-conductive wrapping layer is a semi-conductive nylon tape with a thickness of 0.12 to 0.20 mm. The wrapping method is single-layer overlapping wrapping with an overlap rate of ≥15%.

[0010] The thickness of the silicone rubber insulation layer is controlled between 1.2 and 2.0 mm.

[0011] The non-metallic shielding layer is a semi-conductive silicone shielding layer.

[0012] The silicone rubber insulating layer and the semi-conductive silicone shielding layer are co-extruded in two layers. The semi-conductive silicone shielding layer is densely wrapped around the outside of the silicone rubber insulating layer. The volume resistivity of the semi-conductive silicone at 20°C is ≤100Ω·m. The thickness of the semi-conductive silicone shielding layer is controlled to be 0.6~0.8mm.

[0013] The outer diameter of a single tin-plated copper wire in the metal braided shielding layer is controlled at 0.10–0.20 mm, and the braiding density is controlled at 86%–90%.

[0014] The sheath layer is a halogen-free, low-smoke, flame-retardant silicone rubber sheath layer, and the thickness of the sheath layer is controlled between 1.4 and 2.0 mm.

[0015] The advantages of this utility model after adopting the above solution are that the high thermal conductivity silicone rubber insulated high voltage cable for electric vehicles has high temperature resistance reaching Class F, high thermal conductivity, good insulation resistance, flexibility, good electromagnetic shielding, rated voltage DC 1500V and below, thermal conductivity of insulation layer and sheath layer of 3.0~3.8W / m·K, cable flame retardant performance can reach V-0 (UL94), cable temperature rise test is reduced by 10~20K, effectively solving the temperature rise problem of insulated cable. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this utility model.

[0017] The labels in the diagram are as follows: 1. Soft copper conductor, 2. Semiconductor wrapping layer, 3. Silicone rubber insulation layer, 4. Non-metallic shielding layer, 5. Metal braided shielding layer, 6. Sheath layer. Detailed Implementation

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

[0019] like Figure 1 As shown, this utility model discloses a high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles, which is composed of a soft copper conductor 1, a semi-conductive wrapping layer 2, a silicone rubber insulation layer 3, a non-metallic shielding layer 4, a metal braided shielding layer 5, and a sheath layer 6.

[0020] The soft copper conductor 1 conforms to the performance of the sixth type of soft copper conductor in GB / T 3956-2008, which is a single bare copper wire or a tin-plated copper wire.

[0021] A semi-conductive shielding tape is overlapped and wrapped around the surface of the soft copper conductor 1 to form a semi-conductive wrapping layer 2. The semi-conductive shielding tape can be a semi-conductive nylon tape with a thickness of 0.12 to 0.20 mm. The wrapping method is a single-layer overlapping wrapping with an overlap rate of ≥15%.

[0022] A highly thermally conductive silicone rubber insulating layer 3 and a non-metallic shielding layer 4 are uniformly extruded onto the semi-conductive wrapping layer 2 using a double-layer co-extrusion process. This ensures the non-metallic shielding layer 4 densely covers the outside of the silicone rubber insulating layer 3, forming the insulated wire core. The thickness of the silicone rubber insulating layer 3 is controlled between 1.2 and 2.0 mm. The non-metallic shielding layer 4 is a semi-conductive silicone shielding layer. The volume resistivity of the semi-conductive silicone at 20°C is ≤100 Ω·m, and the thickness of the semi-conductive silicone shielding layer is controlled between 0.6 and 0.8 mm.

[0023] A metal braided shielding layer 5 is formed by braiding tin-plated copper wires outside the non-metallic shielding layer 4. The non-metallic shielding layer 4 and the metal braided shielding layer 5 constitute a composite shielding structure layer. The outer diameter of a single tin-plated copper wire is controlled at 0.10 to 0.20 mm, and the braiding density is controlled at 86% to 90%.

[0024] A highly thermally conductive silicone rubber sheath layer 6 is extruded over the metal braided shielding layer 5. Specifically, the sheath layer 6 can be a highly thermally conductive halogen-free, low-smoke, flame-retardant silicone rubber sheath layer, and the thickness of the sheath layer 6 is controlled between 1.4 and 2.0 mm.

[0025] This invention employs a high thermal conductivity silicone rubber insulation layer 3 and a sheath layer 6, with a thermal conductivity of 3.0–3.8 W / m·K. This reduces cable temperature rise by 10–20 K, effectively solving the problem of cable surface temperature rise and ensuring cable safety. The composite shielding structure of a semi-conductive silicone non-metallic shielding layer 4 and a tinned copper wire braided shielding layer 5 effectively shields against electromagnetic interference. The sheath layer 6 can be supplemented with a low-smoke halogen-free flame retardant, achieving a V-0 (UL94) flame retardancy rating and a long-term temperature resistance rating of F. This makes it suitable for wiring in high-temperature applications in new energy vehicles, such as near exhaust pipes, in front of motors, and behind batteries.

[0026] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high thermal conductivity silicone rubber insulated high-voltage cable for new energy vehicles, characterized in that: It consists of a soft copper conductor, a semiconductive wrapping layer, a silicone rubber insulating layer, a non-metallic shielding layer, a metal braided shielding layer, and a sheath layer. The semiconductive wrapping layer is formed by wrapping a semiconductive shielding tape around the soft copper conductor. The silicone rubber insulating layer and the non-metallic shielding layer are uniformly extruded on the semiconductive wrapping layer. The non-metallic shielding layer is a semiconductive silicone shielding layer. The silicone rubber insulating layer and the semiconductive silicone shielding layer are co-extruded in a double layer. The semiconductive silicone shielding layer is densely covering the outside of the silicone rubber insulating layer. Tin-plated copper wire is braided on the outside of the non-metallic shielding layer to form a metal braided shielding layer. The non-metallic shielding layer and the metal braided shielding layer constitute a composite shielding structure layer. The silicone rubber sheath layer is extruded on the outside of the metal braided shielding layer.

2. The high thermal conductivity silicone rubber insulated high-voltage cable for new energy vehicles according to claim 1, characterized in that: The soft copper conductor conforms to the performance of the sixth type of soft copper conductor in GB / T 3956-2008, which is a single bare copper wire or a tin-plated copper wire.

3. The high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles according to claim 1, characterized in that: The semi-conductive shielding tape of the semi-conductive wrapping layer is a semi-conductive nylon tape with a thickness of 0.12 to 0.20 mm. The wrapping method is single-layer overlapping wrapping with an overlap rate of ≥15%.

4. The high thermal conductivity silicone rubber insulated high-voltage cable for new energy vehicles according to claim 1, characterized in that: The thickness of the silicone rubber insulation layer is controlled between 1.2 and 2.0 mm.

5. The high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles according to claim 1, characterized in that: The volume resistivity of the semi-conductive silicone is ≤100Ω•m at 20℃, and the thickness of the semi-conductive silicone shielding layer is controlled to be 0.6~0.8mm.

6. The high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles according to claim 1, characterized in that: The outer diameter of a single tin-plated copper wire in the metal braided shielding layer is controlled at 0.10–0.20 mm, and the braiding density is controlled at 86%–90%.

7. The high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles according to claim 1, characterized in that: The sheath layer is a halogen-free, low-smoke, flame-retardant silicone rubber sheath layer, and the thickness of the sheath layer is controlled between 1.4 and 2.0 mm.

8. The high thermal conductivity silicone rubber insulated high voltage cable for new energy vehicles according to claim 1, characterized in that: The silicone rubber insulation layer and sheath layer have a thermal conductivity of 3.0 to 3.8 W / m·K, and the flame retardant properties of the materials meet UL94 V-0.

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