Aluminum alloy row cable for new energy automobile

Abstract

The utility model relates to the technical field of new energy cables, and discloses an aluminum alloy row cable for a new energy automobile, which comprises a cable and a mounting plate, the inner wall of the cable is fixedly connected with an insulating layer, the inner wall of the insulating layer is fixedly connected with an aluminum conductor, the outer wall of the cable is fixedly connected with a honeycomb buffer layer, and the honeycomb buffer layer is fixedly connected with the aluminum conductor. The outer wall of the honeycomb buffer layer is fixedly connected with a polyurethane protective layer, the left end and the right end of the cable are fixedly connected with fixing sleeves, the sides, away from each other, of the two fixing sleeves are fixedly connected with threaded connectors, and the outer walls of the threaded connectors are in threaded connection with fastening connecting pieces. In the cable, the aluminum conductor is wrapped by the insulating layer, the aluminum conductor has the characteristics of efficient conduction, lightweight design, high heat dissipation performance, high strength and reliability, and the honeycomb buffer layer is arranged between the wire harness insulating layer and the external polyurethane protective layer, so that a good buffer effect is provided, and the damage to the wire harness caused by collision and friction is reduced.

Description

Technical Field

[0001] This utility model relates to the field of new energy cable technology, and in particular to an aluminum alloy cable for new energy vehicles. Background Technology

[0002] As the global wave of automotive electrification intensifies, countries are accelerating their deployment in the new energy vehicle industry. Technological advancements and the continuous rise in the cost of gasoline vehicles are driving a steady increase in consumer demand for new energy vehicles. This trend is further prompting manufacturers to enhance their product competitiveness and accelerating the rapid growth in new energy vehicle sales. As a core component of power transmission, cables play a crucial role in the vehicle's electrical system. Cables for new energy vehicles are power conduction devices specifically designed to meet the high-power, high-current transmission requirements of new energy vehicles.

[0003] Currently, new energy vehicles use energy storage harnesses, also known as energy storage harnesses or battery pack harnesses. These harnesses are made by combining multiple individual batteries in series or parallel to form a battery pack that can both charge and discharge, and then cleverly connecting them together with a harness. Although traditional copper conductors have stable performance, their high price leads to increased manufacturing costs, and their high density makes copper conductor materials relatively bulky. In addition, long-term use of the harness can cause damage due to collisions and friction. Therefore, an aluminum alloy cable for new energy vehicles is proposed to solve the above problems. Utility Model Content

[0004] To overcome the above shortcomings, this utility model provides an aluminum alloy cable for new energy vehicles, which aims to improve the problem that the high density of copper conductors in the prior art makes copper conductor materials relatively heavy, and that the wire harness will be damaged by collision and friction after long-term use.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An aluminum alloy cable for new energy vehicles includes a cable and an mounting plate. An insulation layer is fixedly connected to the inner wall of the cable, and an aluminum conductor is fixedly connected to the inner wall of the insulation layer. A honeycomb buffer layer is fixedly connected to the outer wall of the cable, and a polyurethane protective layer is fixedly connected to the outer wall of the honeycomb buffer layer. Fixing sleeves are fixedly connected to both ends of the cable, and threaded interfaces are fixedly connected to the opposite sides of the two fixing sleeves. Fastening connectors are threaded to the outer walls of the threaded interfaces.

[0007] As a further description of the above technical solution:

[0008] The mounting plate is provided with a mounting mechanism on its top. The mounting mechanism includes a U-shaped buckle. The U-shaped buckle is installed on the outer wall of the fastening connector. Insert plates are fixedly connected to the front and rear sides of the U-shaped buckle. Connecting grooves are opened on the front and rear sides of the top of the mounting plate. A fastening bolt is threaded to the top of the U-shaped buckle. The bottom end of the fastening bolt passes through the top of the U-shaped buckle and is rotatably connected to a rubber extrusion plate.

[0009] As a further description of the above technical solution:

[0010] The installation mechanism also includes multiple protrusions, all of which are fixedly connected to the front and rear sides of the U-shaped buckle.

[0011] As a further description of the above technical solution:

[0012] The outer wall of each fastener is provided with multiple grooves, which are arranged at equal intervals.

[0013] As a further description of the above technical solution:

[0014] The mounting plate has screw holes on both the front and rear sides of its top, and bolts are threaded into the inner sides of the two screw holes.

[0015] As a further description of the above technical solution:

[0016] The diameter of the bolt is matched with the inner diameter of the bolt hole, and a perforated groove is provided at the top of the bolt.

[0017] As a further description of the above technical solution:

[0018] The bolt has an anti-slip groove on the top of its outer wall, and the outer wall of the anti-slip groove is rounded.

[0019] As a further description of the above technical solution:

[0020] The mounting plate has a fitting groove on its top, and multiple rubber strips are fixedly connected to the top of the fitting groove.

[0021] This utility model has the following beneficial effects:

[0022] 1. In this utility model, the cable is wrapped with an insulation layer around an aluminum conductor. The aluminum conductor has the characteristics of high conductivity, lightweight design, high heat dissipation performance, high strength and reliability. The honeycomb buffer layer is set between the wire harness insulation layer and the outer polyurethane protective layer to construct a honeycomb-shaped buffer structure. The honeycomb unit can be made of lightweight and high-strength plastic or composite material. Its regular hexagonal structure can effectively disperse external impact force, provide good buffering effect, and reduce damage to the wire harness caused by collision and friction.

[0023] 2. In this utility model, the cable is divided into several segments along its length. The length of each segment is determined according to the actual situation of the wiring inside the vehicle and the stress characteristics. Threaded interfaces for connecting fasteners are reserved at both ends of each cable segment to facilitate connection. U-shaped buckles are placed on the fasteners and inserted into the connecting slots via insert plates. Finally, the fastener is rotated to drive the rubber extrusion plate and rubber strip to extrude the fasteners. The rubber material can prevent the fasteners from loosening due to vibration and pulling, thus completing quick installation and facilitating disassembly. Attached Figure Description

[0024] Figure 1 This is a cross-sectional view of an aluminum alloy cable tray for new energy vehicles according to the present invention.

[0025] Figure 2 This is a perspective view of an aluminum alloy cable tray for new energy vehicles according to the present invention.

[0026] Figure 3 This is an exploded view of the threaded interface of an aluminum alloy cable for new energy vehicles according to this utility model.

[0027] Figure 4 This is an exploded view of the installation mechanism of an aluminum alloy cable tray for new energy vehicles according to this utility model;

[0028] Figure 5 This is a side view of an installation mechanism for an aluminum alloy cable tray used in new energy vehicles according to this utility model.

[0029] Legend:

[0030] 1. Cable; 2. Installation mechanism; 201. U-shaped buckle; 202. Insert plate; 203. Connecting groove; 204. Fastening bolt; 205. Rubber extrusion plate; 206. Protrusion; 3. Aluminum conductor; 4. Insulation layer; 5. Honeycomb buffer layer; 6. Polyurethane protective layer; 7. Mounting plate; 8. Fixing sleeve; 9. Threaded interface; 10. Fastening connector; 11. Groove; 12. Screw hole; 13. Bolt; 14. Pleated groove; 15. Anti-slip groove; 16. Fitting groove; 17. Rubber strip. Detailed Implementation

[0031] 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.

[0032] Reference Figure 1 , Figure 2 and Figure 3 This utility model provides an embodiment of an aluminum alloy cable for new energy vehicles, comprising a cable 1 and a mounting plate 7. An insulation layer 4 is fixedly connected to the inner wall of the cable 1, and an aluminum conductor 3 is fixedly connected to the inner wall of the insulation layer 4. The aluminum conductor 3 has a cross-sectional area of ​​16–240 mm². 2 This material features high conductivity, lightweight design, high heat dissipation, high strength, and high reliability; it is also easy to install and maintain. A honeycomb buffer layer 5 is fixedly connected to the outer wall of cable 1, and a polyurethane protective layer 6 is fixedly connected to the outer wall of the honeycomb buffer layer 5. The honeycomb buffer layer 5 forms a honeycomb-shaped buffer structure between the wire harness insulation layer 4 and the outer polyurethane protective layer 6. The honeycomb units can be made of lightweight and high-strength plastics or composite materials. Its regular hexagonal structure effectively disperses external impact forces, providing a good buffering effect and reducing damage to the wire harness caused by collisions and friction. At the same time, the honeycomb structure itself is lightweight, which helps to lift the wire harness. While improving wear resistance, it does not significantly increase the overall weight, which helps to achieve the goal of lightweighting. The left and right ends of the cable 1 are fixedly connected to the fixing sleeves 8. The two fixing sleeves 8 are fixedly connected to the opposite side of the two fixing sleeves 8 with threaded interfaces 9. The outer wall of the threaded interface 9 is threaded with fastening connectors 10, which divides the cable 1 into several segments along the length direction, so as to more accurately cope with the stress of different parts. The two ends of each segment of the cable 1 are reserved with threaded interfaces 9 for connecting to the fastening connectors 10, so as to facilitate the connection with the fastening connectors 10. The outer wall of the fastening connectors 10 is provided with multiple grooves 11, which are arranged at equal intervals.

[0033] The top of the mounting plate 7 is provided with a mounting mechanism 2, which is used to quickly install and remove the cable 1.

[0034] Specifically, the inner wall of cable 1 is fixed with an insulation layer 4, and the inner wall of the insulation layer 4 is fixed with an aluminum conductor 3. The cross-sectional area of ​​the aluminum conductor 3 is designed to be between 16 and 240 square millimeters, and its geometry is rectangular. Through continuous casting, continuous rolling, continuous extrusion or other advanced manufacturing processes, a solid rectangular aluminum alloy conductor is formed. This aluminum alloy conductor not only has high conductivity but also achieves lightweight design. The outer wall of cable 1 is fixed with a honeycomb buffer layer 5, and the outer wall of the honeycomb buffer layer 5 is further fixed with a polyurethane protective layer 6. The honeycomb buffer layer 5 constructs a honeycomb-shaped buffer structure, located between the wire harness insulation layer 4 and the outer polyurethane protective layer 6. These honeycomb units can be made of lightweight and high-strength plastic or Made of composite materials, its regular hexagonal structure effectively disperses external impact forces, providing excellent cushioning and reducing damage to the wiring harness caused by collisions or friction. Simultaneously, due to the lightweight nature of the honeycomb structure, it enhances the wear resistance of the wiring harness without significantly increasing the overall weight, contributing to weight reduction. Both ends of the cable 1 are fixed with retaining sleeves 8, and each retaining sleeve 8 has a threaded interface 9 fixed on its opposite side. This allows the cable 1 to be divided into several segments along its length, the length of which is determined based on the actual wiring configuration and stress characteristics within the vehicle. The installation mechanism 2 is used for quick installation and removal of the cable 1, greatly improving installation and maintenance efficiency.

[0035] Reference Figure 2 , Figure 4 and Figure 5 The installation mechanism 2 includes a U-shaped buckle 201, which is installed on the outer wall of the fastening connector 10. Insert plates 202 are fixedly connected to both the front and rear sides of the U-shaped buckle 201. The U-shaped buckle 201 and the insert plates 202 are integrally formed, improving overall stability. Connecting grooves 203 are provided on both the front and rear sides of the top of the mounting plate 7. First, the U-shaped buckle 201 is placed on the fastening connector 10, and the insert plates 202 on both sides are aligned with the connecting grooves 203 and slidably inserted to complete the initial installation of the cable 1. A fastening bolt 204 is threaded to the top of the U-shaped buckle 201. The bottom end of the fastening bolt 204 passes through the top of the U-shaped buckle 201 and is rotatably connected to a rubber extrusion plate 205. Hidden on the top of the inner wall of the U-shaped buckle 201, the rubber extrusion plate 205 is driven by rotating the fastening bolt 204 to extrude the fastening connector 10. The installation mechanism 2 also includes multiple protrusions 206, which are fixedly connected to the front and rear sides of the U-shaped buckle 201. The top front and rear sides of the mounting plate 7 are provided with screw holes 12, and bolts 13 are threaded into the inner side of the two screw holes 12. The top of the mounting plate 7 is provided with a fitting groove 16, and multiple rubber strips 17 are fixedly connected to the top of the fitting groove 16. The rubber strips 17 in the fitting groove 16 are used to fix the fastening connector 10. The rubber material can prevent the fastening connector 10 from loosening due to vibration and pulling.

[0036] Specifically, the U-shaped buckle 201 and the insert plate 202 are integrally formed, which significantly improves the overall structural strength. Furthermore, the mounting plate 7 has connecting grooves 203 on both the front and rear sides of its top. During installation, the U-shaped buckle 201 is first placed on the fastening connector 10, and then the insert plates 202 on both sides are aligned with the connecting grooves 203 and slid in to complete the initial installation of the cable 1. To further enhance the fixing effect, the top of the U-shaped buckle 201 is threaded to connect to the fastening bolt 204. The bottom end of the fastening bolt 204 passes through the top of the U-shaped buckle 201 and is rotatably connected to a rubber extrusion plate 205. 05 is cleverly hidden on the top of the inner wall of the U-shaped buckle 201. When the fastening bolt 204 is rotated, it will drive the rubber extrusion plate 205 to squeeze the fastening connector 10, thereby ensuring the stability of the connection. In addition, the installation mechanism 2 also includes multiple protrusions 206, which are fixed on the front and rear sides of the U-shaped buckle 201 for easy handling and to prevent slippage. The rubber strip 17 works in conjunction with the fitting groove 16 to fix the fastening connector 10. Due to the use of rubber material, it can effectively prevent the fastening connector 10 from loosening when subjected to vibration or pulling, thereby ensuring the stability and reliability of the entire installation structure.

[0037] Reference Figure 2 , Figure 4 and Figure 5 The diameter of the bolt 13 is matched with the inner diameter of the screw hole 12. The top of the bolt 13 is provided with a plum blossom groove 14, and the top of the outer wall of the bolt 13 is provided with an anti-slip groove 15. The outer wall of the anti-slip groove 15 is rounded.

[0038] Specifically, the diameter of bolt 13 is perfectly matched with the inner diameter of screw hole 12, ensuring that bolt 13 can be smoothly inserted into screw hole 12. For ease of operation, a Torx groove 14 is designed at the top of bolt 13, which can be tightened or loosened using a Torx wrench. In addition, an anti-slip groove 15 is specially provided on the top of the outer wall of bolt 13 to increase the friction when gripping and prevent slipping. To further improve the safety and comfort during use, the outer wall of the anti-slip groove 15 has been rounded to avoid discomfort or injury caused by sharp edges.

[0039] Working principle: First, the cable 1 is wrapped with an insulation layer 4 to enclose the aluminum conductor 3. The honeycomb buffer layer 5 is set between the wire harness insulation layer 4 and the outer polyurethane protective layer 6 to construct a honeycomb-shaped buffer structure. The honeycomb unit can be made of lightweight and high-strength plastic or composite material. Its regular hexagonal structure can effectively disperse external impact force, provide good buffering effect, and reduce damage to the wire harness due to collision and friction.

[0040] Furthermore, the cable 1 is divided into several segments along its length. The length of each segment is determined based on the actual wiring conditions and stress characteristics of the vehicle's interior. In areas with high vibration and tensile forces, such as the chassis, the segments can be relatively short to more accurately handle the stress on different parts. In the relatively stable interior of the cockpit, the segments can be appropriately longer. Threaded interfaces 9 for connecting and fastening the fasteners 10 are reserved at both ends of each cable segment 1. During installation, the U-shaped buckle 201 is first placed on the fastener 10, and the insert plates 202 on both sides are aligned with the connecting grooves 203 and slid in to complete the initial installation of the cable 1. The fastening bolt 204 is rotated to drive the rubber extrusion plate 205 to extrude the fastener 10, which, together with the rubber strip 17 in the fitting groove 16, completes the fixing of the fastener 10.

[0041] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An aluminum alloy cable for new energy vehicles, comprising a cable (1) and a mounting plate (7), characterized in that: An insulation layer (4) is fixedly connected to the inner wall of the cable (1), and an aluminum conductor (3) is fixedly connected to the inner wall of the insulation layer (4). A honeycomb buffer layer (5) is fixedly connected to the outer wall of the cable (1), and a polyurethane protective layer (6) is fixedly connected to the outer wall of the honeycomb buffer layer (5). A fixing sleeve (8) is fixedly connected to both the left and right ends of the cable (1). A threaded interface (9) is fixedly connected to the opposite side of the two fixing sleeves (8). A fastening connector (10) is threaded to the outer wall of the threaded interface (9).

2. The aluminum alloy cable for new energy vehicles according to claim 1, characterized in that: The mounting plate (7) is provided with a mounting mechanism (2) on its top. The mounting mechanism (2) includes a U-shaped buckle (201). The U-shaped buckle (201) is installed on the outer wall of the fastening connector (10). The front and rear sides of the U-shaped buckle (201) are fixedly connected with insert plates (202). The front and rear sides of the top of the mounting plate (7) are provided with connecting grooves (203). The top of the U-shaped buckle (201) is threadedly connected with a fastening bolt (204). The bottom end of the fastening bolt (204) passes through the top of the U-shaped buckle (201) and is rotatably connected with a rubber extrusion plate (205).

3. The aluminum alloy cable for new energy vehicles according to claim 2, characterized in that: The mounting mechanism (2) also includes a plurality of protrusions (206), which are fixedly connected to the front and rear sides of the U-shaped buckle (201).

4. The aluminum alloy cable for new energy vehicles according to claim 1, characterized in that: The outer wall of each fastening connector (10) is provided with a plurality of grooves (11), and the plurality of grooves (11) are arranged at equal intervals.

5. The aluminum alloy cable for new energy vehicles according to claim 1, characterized in that: The mounting plate (7) has screw holes (12) on both the front and rear sides of its top, and bolts (13) are threaded into the inner sides of the two screw holes (12).

6. The aluminum alloy cable for new energy vehicles according to claim 5, characterized in that: The diameter of the bolt (13) is matched with the inner diameter of the screw hole (12), and a plum blossom groove (14) is provided at the top of the bolt (13).

7. The aluminum alloy cable for new energy vehicles according to claim 6, characterized in that: The top of the outer wall of the bolt (13) is provided with an anti-slip groove (15), and the outer wall of the anti-slip groove (15) is rounded.

8. The aluminum alloy cable for new energy vehicles according to claim 1, characterized in that: The mounting plate (7) has a fitting groove (16) on its top, and a plurality of rubber strips (17) are fixedly connected to the top of the fitting groove (16).

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