Cable for heavy truck
The heavy-duty truck cable, with its multi-layer structure design, solves the problems of high temperature resistance, scratch resistance, and corrosion resistance of chassis cables in extreme environments, achieving wide-range temperature resistance and wiring adaptability, and improving the reliability and service life of the cable.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHANGCHUN FORCE AUTOMOTIVE WIRE CO LTD
- Filing Date
- 2025-05-09
- Publication Date
- 2026-05-05
AI Technical Summary
Heavy truck chassis cables have insufficient performance under high temperature, severe vibration, oil corrosion and extreme cold environments. Existing technology cannot simultaneously meet the requirements of high temperature resistance, scratch resistance and corrosion resistance, resulting in frequent cable failures, affecting reliability and service life.
The cable design uses an insulation layer, an inner sheath, and a polymer sheath made of polymer materials, combined with oxygen-free copper wire conductors and reinforcing wires to form a multi-layer structure, including conductors, insulation layers, inner sheaths, tensile layers, and sheaths, which enhances temperature resistance and mechanical strength.
The cable's temperature range has been extended to -40 to 200°C, improving its flexibility and resistance to extreme environments, extending its service life, and simplifying wiring and installation.
Smart Images
Figure CN224203868U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automotive wiring harness technology, and in particular to a cable for heavy-duty trucks. Background Technology
[0002] With the expansion of the global commercial vehicle market, the demand for heavy-duty trucks exported to extreme climate regions has surged, posing severe environmental challenges to their chassis wiring harnesses. Chassis wiring harnesses are exposed to high temperatures, severe vibrations, oil erosion, and extremely cold environments for extended periods, rendering traditional cables inadequate for reliability requirements. Current technologies for heavy-duty truck chassis cables generally employ a single-structure design with a conductor and a PVC insulation layer, which has significant drawbacks: First, insufficient temperature resistance; conventional cables have a temperature range of -40 to 105°C, failing to cope with the instantaneous thermal shock in high-temperature regions and the embrittlement issues in extremely cold environments. Second, weak mechanical durability; existing cables only meet the minimum requirements of national standards in abrasion tests, and are prone to sheath cracking under extreme conditions such as sand and gravel splashes and road impacts, leading to conductor exposure. Third, lack of resistance to chemical media; the PVC insulation layer is prone to swelling and failure under long-term corrosion from liquids such as diesel and de-icing agents, accelerating cable aging. Fourth, contradictory material properties; traditional technologies require high-hardness materials to improve temperature resistance, which in turn reduces flexibility and makes the cables more susceptible to micro-cracks due to stress concentration in vibration environments. Although the industry has tried to improve performance by increasing the thickness of the sheath or by localizing reinforcement, it has not solved the problem of synergistic optimization of multiple performance aspects such as high temperature resistance, scratch resistance, and corrosion resistance. This has led to frequent cable failures in exported vehicles, which seriously restricts the reliability and service life of heavy trucks in harsh environments. Utility Model Content
[0003] In order to overcome the above-mentioned technical defects, the present invention provides a cable for heavy-duty trucks to solve at least one technical problem existing in the background art.
[0004] This utility model provides the following technical solution: a cable for heavy trucks, comprising several conductors 1, wherein the conductors 1 are sequentially covered by an insulation layer 2, an inner sheath 3, a tensile layer 4, and a sheath layer 5, wherein the tensile layer 4 is used to prevent external vibration from entering the cable interior, and the conductors 1 include intertwined metal wires and reinforcing wires, wherein the metal wires are used to conduct electricity, and the reinforcing wires are used to increase tensile and bending strength.
[0005] Furthermore, the metal wire is an oxygen-free copper wire with a purity of 99.99% or higher, used to enhance the conductivity of the cable, and the diameter of the oxygen-free copper wire is less than or equal to 0.4 mm.
[0006] Furthermore, the reinforcing wire includes bulletproof wire, copper alloy monofilament, or copper-clad steel wire.
[0007] Furthermore, the insulating layer 2 is made of a polymer material, the Shore hardness of the insulating layer 2 is D90±20, the temperature resistance range of the insulating layer 2 is -40~150℃, the withstand voltage of the insulating layer 2 is 600V, and the concentricity of the insulating layer 2 is ≥95%.
[0008] Furthermore, the insulation layer 2 covers the conductor 1 to form a wire, and the wire is stranded after being twisted by a de-twisting cable bundler, cage stranding or tube stranding.
[0009] Furthermore, the stranded wire is a stable stranded structure formed in the range of 15 to 80 mm by untwisting the wire.
[0010] Furthermore, the inner protective layer 3 is an elastomer foam structure, the thickness of the elastomer is 0.5 to 1.5 mm, the hardness of the inner protective layer 3 is 75 to 95 A, and the temperature resistance range of the inner protective layer 3 is -40 to 150℃.
[0011] Furthermore, the tensile layer 4 includes a braided mesh made of woven polyester filaments, which is used to prevent external vibrations from entering the cable.
[0012] Furthermore, the sheath layer 5 is made of polymer material, the thickness of the sheath layer 5 is 0.5 to 2 mm, and the temperature resistance range of the sheath layer 5 is -40 to 200℃.
[0013] The technical effects and advantages of this utility model are as follows:
[0014] 1. Wide temperature resistance: The cable's temperature resistance range is extended to -40 to 200℃, filling the gap in the high-temperature resistant reel cable market;
[0015] 2. Multifunctional integrated design: Supports multi-branch structure configuration, flexibly adapting to diverse functional requirements such as ABS and ESP;
[0016] 3. Improved cabling adaptability: Excellent temperature resistance reduces cabling space limitations and simplifies installation complexity;
[0017] 4. Enhanced environmental resistance: Structural optimization improves resistance to extreme temperature shocks, mechanical stress, and chemical corrosion, extending cable life;
[0018] 5. Enhanced product scalability: The development of a series of specialized cables for harsh environments enriches the cable solutions for commercial vehicles. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the three conductor structure of this utility model;
[0020] Figure 2 This is a schematic diagram of the two conductors of this utility model;
[0021] Figure 3 This is a schematic diagram of a conductor structure of this utility model;
[0022] Figure 4 This is a schematic diagram of the six conductor structure of this utility model.
[0023] Among them, 1. conductor; 2. insulation layer; 3. inner sheath; 4. tensile layer; 5. sheath layer. Detailed Implementation
[0024] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. This utility model is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0025] Reference Figures 1 to 4 As shown, this utility model provides a cable for heavy-duty trucks, including a conductor 1 made of stranded metal wires. The metal wires include oxygen-free copper wires with tin-plated or bare copper surfaces. The purity of the oxygen-free copper wires is above 99.99% to ensure the conductivity of the conductor 1.
[0026] The diameter of the oxygen-free copper wire is less than or equal to 0.4 mm. The conductor 1 is also provided with reinforcing wires, which include bulletproof wires, copper alloy monofilaments, and copper-clad steel wires. The reinforcing wires are twisted with the oxygen-free copper wires to form a high-quality or ultra-high-quality conductor 1, so as to achieve that the conductor 1 is flexible and has high tensile strength and excellent bending performance, thereby improving the bending life of the cable.
[0027] The conductor 1 is covered with an insulating layer 2, which is made of a polymer material with a Shore hardness of D 90±20 through an extrusion process. The polymer material includes polypropylene, cross-linked polyethylene copolymer, or silicone rubber. The insulating layer 2 has a temperature resistance of -40 to 150℃, a withstand voltage of 600V, and a concentricity ≥95%. During a low-temperature winding test at -40℃, the insulating layer 2 does not exhibit surface cracking or whitening.
[0028] The insulation layer 2 covers the conductor 1 to form a wire, which is then stranded using a de-twisting stranding machine, cage stranding, or tubular stranding to create a stranded wire. The conductor 1 is configured with multiple strands according to the transmitted signal and / or current, as shown in the reference. Figures 1 to 4 As shown, conductor 1 is configured with 3, 2, 1, and 6 conductors.
[0029] The stranded wire is a stable stranded structure formed by the wire within the range of 15-80mm. During the stranding process, the wire is untwisted to achieve a stable stranded structure, uniform stranding pitch, and elimination of internal stress.
[0030] The stranded wire is covered with an inner sheath 3, which is an extruded physical or chemical foam structure. The hardness of the inner sheath 3 is 75 to 95A, the temperature resistance range is -40 to 150℃, and the material of the inner sheath 3 is an elastomer, including cross-linked polyethylene, polyurethane, or polypropylene. The thickness of the elastomer is 0.5 to 1.5 mm. It is used to stabilize the stranded wire structure and prevent changes in the twisted wire pitch caused by external environmental factors such as bending, vibration, impact, or erosion, thereby maintaining stable signal transmission and preventing signal interruption.
[0031] The inner sheath 3 is covered by a tensile layer 4, which comprises a braided mesh made of woven polyester filaments. The braided mesh is used to prevent external vibrations from penetrating the internal structure of the cable and to avoid stress on the internal wire cores. The braided mesh also prevents cable bending and movement caused by vertical vibrations from harsh truck driving environments.
[0032] The tensile layer 4 is covered by a sheath layer 5, which is made of extruded polypropylene, polyurethane, or silicone rubber, and has a thickness of 0.5 to 2 mm. The silicone rubber is vulcanized silicone rubber, and the polyurethane is unvulcanized polyurethane, used to form a cable protective layer. The sheath layer 5 has a temperature resistance of -40 to 200°C, thus providing long-term insulation from the external high-temperature environment and protecting the internal safety of the cable.
[0033] The present invention provides a cable for heavy-duty trucks that can be used for wiring in environments up to 200°C.
[0034] It should be understood that, firstly, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship may change.
[0035] Secondly: The accompanying drawings of the embodiments disclosed in this utility model only involve the structures involved in the embodiments disclosed in this utility model. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this utility model can be combined with each other.
[0036] Finally: The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. 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. A cable for heavy-duty trucks, comprising a plurality of conductors (1), each conductor (1) being sequentially covered by an insulation layer (2), an inner sheath (3), a tensile layer (4), and a sheath layer (5), wherein the tensile layer (4) is used to prevent external vibrations from penetrating the cable interior, characterized in that, The conductor (1) comprises intertwined metal wires and reinforcing wires, the metal wires being used to conduct electricity and the reinforcing wires being used to increase tensile and bending strength.
2. The cable for heavy-duty trucks according to claim 1, characterized in that: The metal wire is an oxygen-free copper wire with a purity of 99.99% or higher, used to enhance the conductivity of the cable. The diameter of the oxygen-free copper wire is less than or equal to 0.4 mm.
3. The cable for heavy-duty trucks according to claim 1, characterized in that: The reinforcing wire includes bulletproof wire, copper alloy monofilament, or copper-clad steel wire.
4. The cable for heavy-duty trucks according to claim 1, characterized in that: The insulating layer (2) is made of polymer material, the Shore hardness of the insulating layer (2) is D 90±20, the temperature resistance range of the insulating layer (2) is -40~150℃, the withstand voltage of the insulating layer (2) is 600V, and the concentricity of the insulating layer (2) is ≥95%.
5. A cable for heavy-duty trucks according to claim 1, characterized in that: The insulation layer (2) covers the conductor (1) to form a wire, and the wire is made into a stranded wire by being twisted by a de-twisting bundling machine, cage stranding or tube stranding.
6. A cable for heavy-duty trucks according to claim 5, characterized in that: The stranded wire is a stable stranded structure formed in the range of 15 to 80 mm by untwisting the wire.
7. A cable for heavy-duty trucks according to claim 1, characterized in that: The inner protective layer (3) is an elastomer foam structure with a thickness of 0.5 to 1.5 mm, a hardness of 75 to 95 A, and a temperature resistance range of -40 to 150 °C.
8. A cable for heavy-duty trucks according to claim 1, characterized in that: The tensile layer (4) includes a braided mesh made of woven polyester filaments, which is used to prevent external vibrations from entering the cable.
9. A cable for heavy-duty trucks according to claim 1, characterized in that: The sheath layer (5) is made of polymer material, the thickness of the sheath layer (5) is 0.5 to 2 mm, and the temperature resistance range of the sheath layer (5) is -40 to 200℃.