New energy vehicle cable

Abstract

The utility model discloses a cable for a new energy vehicle, which comprises a conductor layer positioned on the innermost layer, a first insulating layer coated on the outer surface of the conductor layer, an inner shielding layer fixedly arranged on the outer side of the first insulating layer, a second insulating layer fixedly arranged on the outer side of the inner shielding layer, and an outer shielding layer fixedly arranged on the outer side of the second insulating layer, by means of the composite structural design of the conductor layer, the double insulating layers, the double shielding layers, the heat dissipation layer and the outer sheath, the problems that an existing cable is poor in electromagnetic compatibility, insufficient in temperature resistance and low in heat dissipation efficiency are solved. The material combination and spatial arrangement of the shielding layer and the insulating layer are particularly optimized, the comprehensive performance is remarkably improved while the flexibility is ensured, and the cable is suitable for complex working conditions of a high-voltage system of a new energy vehicle.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage cable technology for new energy vehicles, specifically a high-performance cable with a multi-layer composite structure, suitable for high-voltage power transmission in electric vehicle power batteries, motors, and charging systems. Background Technology

[0002] Existing cables for new energy vehicles have many problems: they adopt a single-layer shielding structure, which is prone to electromagnetic interference under high-voltage and high-frequency conditions; the traditional insulation layer has a low temperature resistance level, with a maximum of only ≤125℃, and is prone to cracking after long-term bending; some cables use metal sheaths for heat dissipation, which reduces the cable's flexibility and makes it difficult to adapt to the wiring needs of the narrow space inside the vehicle. Utility Model Content

[0003] (I) Technical Issues

[0004] This invention provides a new energy vehicle cable with composite shielding, high temperature resistance, excellent dynamic heat dissipation, and lightweight design, in order to solve the problems of electromagnetic interference, insufficient temperature resistance, contradiction between heat dissipation and flexibility, and heavy weight of existing cables.

[0005] (II) Technical Content

[0006] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows: a cable for new energy vehicles, including an innermost conductor layer, which is made of multiple strands of tin-plated copper wires twisted together. The conductor layer is covered with a first insulation layer. An inner shielding layer is fixedly provided outside the first insulation layer. A second insulation layer is fixedly provided outside the inner shielding layer. An outer shielding layer is fixedly provided outside the second insulation layer. A heat dissipation layer is fixedly provided outside the outer shielding layer. An outer sheath is fixedly provided outside the heat dissipation layer.

[0007] Furthermore, the first insulating layer is made of cross-linked polyethylene material.

[0008] Furthermore, the inner shielding layer is a woven copper wire mesh structure.

[0009] Furthermore, the second insulating layer is made of a composite of silicone rubber and ceramic particles.

[0010] Furthermore, the heat dissipation layer is composed of a spirally wound metal wire and thermally conductive silicone, wherein the metal wire is a nickel-plated copper wire.

[0011] Furthermore, the outer sheath is made of flame-retardant thermoplastic polyurethane material, and the surface of the outer sheath is provided with axially distributed raised stripes.

[0012] Furthermore, the outer shielding layer is an aluminum-plastic composite tape wrapping layer.

[0013] (III) Technical Effects

[0014] The advantages of this utility model compared with the prior art are as follows:

[0015] 1. High-efficiency composite shielding: The inner braided copper wire mesh shielding layer and the outer aluminum-plastic composite tape wrapping shielding layer work together to effectively suppress high-frequency and low-frequency interference, improving shielding effectiveness by over 40%.

[0016] 2. High temperature resistance and bending resistance: The second insulation layer, made of silicone rubber and ceramic particles, has a temperature resistance rating of up to 180℃ and a bending life of 3 times.

[0017] 3. Excellent dynamic heat dissipation: The heat dissipation layer composed of spirally wound nickel-plated copper wire and thermally conductive silicone can maintain the heat conduction channel even when the cable is bent. Combined with the axially distributed raised stripes on the surface of the outer sheath to increase the heat dissipation area, the temperature rise can be reduced by 15-20℃.

[0018] 4. Achieve lightweight design: Through layered optimization design, the weight is reduced by 25% compared to traditional cables of the same specifications, meeting the lightweight development needs of new energy vehicles. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of a cable for new energy vehicles according to this utility model. Figure 1 .

[0020] Figure 2 This is a three-dimensional structural diagram of a cable for new energy vehicles according to this utility model. Figure 2 .

[0021] Figure 3 This is a schematic diagram of the main structure of a cable for new energy vehicles according to this utility model.

[0022] As shown in the figure: 1. Conductor layer; 2. First insulating layer; 3. Inner shielding layer; 4. Second insulating layer; 5. Outer shielding layer; 6. Heat dissipation layer; 7. Outer sheath; 8. Raised stripes. Detailed Implementation

[0023] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", "center", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation structure and operation. Therefore, they should not be construed as limitations on this utility model.

[0024] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "provided with," "installed," "connected," "linked," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0025] The present invention will now be described in further detail with reference to the accompanying drawings.

[0026] Combined with appendix Figure 1 To be continued Figure 3 A new energy vehicle cable includes an innermost conductor layer 1, which is made of multiple strands of tin-plated copper wire. A first insulation layer 2, made of cross-linked polyethylene, is covered on the outer surface of the conductor layer 1. An inner shielding layer 3, which is a braided copper wire mesh structure, is fixedly installed on the outer surface of the first insulation layer 2. A second insulation layer 4, made of a composite of silicone rubber and ceramic particles, is fixedly installed on the outer surface of the second insulation layer 4. The outer shielding layer 5 is an aluminum-plastic composite tape wrapping layer. A heat dissipation layer 6, made of a composite of spirally wound metal wire and thermally conductive silicone, is fixedly installed on the outer surface of the outer shielding layer 5. The metal wire is nickel-plated copper wire. An outer sheath 7, made of flame-retardant thermoplastic polyurethane, is fixedly installed on the outer surface of the heat dissipation layer 6. The outer sheath 7 has axially distributed raised stripes 8 on its surface.

[0027] The working principle of the layered structure of this utility model is as follows:

[0028] Conductor layer 1: Composed of multiple strands of tin-plated copper wire. The tin plating prevents oxidation of the copper wire and improves conductivity and stability. The multi-strand stranded structure increases the cable's flexibility, facilitating wiring within the vehicle. Its main function is to serve as a carrier for current transmission, delivering electrical energy to various electrical devices in new energy vehicles.

[0029] First insulation layer 2: Made of cross-linked polyethylene material, it has good electrical insulation properties, can effectively isolate the current in the conductor layer, prevent current leakage, ensure electrical safety, and at the same time play a mechanical protection role for the conductor layer.

[0030] Inner shielding layer 3: It is a braided copper wire mesh structure. Utilizing the good conductivity of copper, it shields the high-frequency electromagnetic interference generated inside the cable, preventing it from interfering with other external electronic devices. At the same time, it can also prevent external high-frequency electromagnetic interference from entering the cable and affecting the stability of current transmission.

[0031] The second insulating layer 4 is made of silicone rubber and ceramic particles. Silicone rubber has good flexibility and insulation, while ceramic particles improve the material's high-temperature resistance. The combination of the two increases the insulation layer's temperature resistance to 180℃, meeting the requirements of new energy vehicles under high-temperature conditions. At the same time, it significantly improves the bending life, preventing the insulation layer from cracking due to long-term bending and ensuring the durability of insulation performance.

[0032] Outer shielding layer 5: This is an aluminum-plastic composite tape wrapping layer. The aluminum layer in the aluminum-plastic composite tape can effectively shield low-frequency electromagnetic interference, further enhancing the shielding effect of the cable. Together with the inner shielding layer, it can achieve comprehensive suppression of electromagnetic interference of different frequencies and ensure the purity of cable signal transmission.

[0033] Heat dissipation layer 6: Composed of spirally wound nickel-plated copper wire and thermally conductive silicone. The nickel-plated copper wire has excellent thermal conductivity, and the spiral winding method maintains a continuous heat conduction channel even when the cable is bent. The thermally conductive silicone fills the spaces between the nickel-plated copper wire, enhancing the overall thermal conductivity. Working together, these two components rapidly dissipate the heat generated during cable operation. Combined with the raised stripes on the outer sheath surface to increase the heat dissipation area, they reduce cable temperature rise and ensure stable cable operation at suitable temperatures.

[0034] Outer sheath 7: Made of flame-retardant thermoplastic polyurethane material, it has good wear resistance, corrosion resistance, and flame retardancy. It protects the internal structure from external physical damage and chemical erosion, and can delay the spread of fire in the event of a fire, improving the safety of cable use. The axially distributed raised stripes 8 on the surface not only increase the heat dissipation area but also improve the cable's anti-slip performance to a certain extent, facilitating installation and fixing.

[0035] This embodiment provides a cable manufacturing process, the steps of which are as follows:

[0036] 1. Conductor Layer Fabrication: High-quality copper wire is selected and tin-plated to enhance its oxidation resistance and conductivity. Using stranding equipment, multiple strands of tin-plated copper wire are stranded at a specific pitch and direction to form a conductor layer with good flexibility and conductivity. After stranding, the conductor resistance and appearance quality must be tested to ensure compliance with standards.

[0037] 2. First Insulation Layer Coating: Using an extrusion process, cross-linked polyethylene raw material is fed into an extruder, heated and melted, and then uniformly extruded over the conductor layer through a specific die. After extrusion, cross-linking treatment is performed, using either chemical cross-linking or radiation cross-linking methods to improve insulation and mechanical properties. Finally, the insulation thickness, eccentricity, and insulation resistance are tested.

[0038] 3. Inner Shielding Layer Installation: Using braiding equipment, copper wires are braided into a copper wire mesh at appropriate braiding angles and densities, tightly wrapping it around the first insulation layer. The braiding process must ensure uniform mesh size and no broken wires. After completion, check the braiding coverage and shielding effect.

[0039] 4. Fabrication of the second insulation layer: Silicone rubber and ceramic particles are mixed in a certain proportion and thoroughly mixed evenly using an internal mixer. Then, using an extrusion process, the mixed material is extruded onto the outside of the inner shielding layer. After vulcanization, the material is cross-linked and cured to form a stable composite insulation structure. Subsequently, the insulation performance and physical and mechanical properties are tested.

[0040] 5. Outer Shielding Layer Wrapping: Install the aluminum-plastic composite tape on the wrapping equipment and spirally wrap it around the second insulation layer at the set overlap and tension. Keep the tape flat and tight during the wrapping process. After wrapping, check the wrapping quality and shielding performance.

[0041] 6. Heat Dissipation Layer Construction: Nickel-plated copper wire is spirally wound around the outer shielding layer at a specific pitch. Simultaneously, thermally conductive silicone is evenly filled into the gaps between the nickel-plated copper wire, ensuring a tight bond between the two and forming a highly efficient heat dissipation structure. After fabrication, the thermal conductivity and structural stability of the heat dissipation layer are tested.

[0042] 7. Outer Sheath Extrusion: Flame-retardant thermoplastic polyurethane raw material is fed into an extruder, heated and plasticized, and then extruded through a die with special grooves to cover the heat dissipation layer, forming axially distributed raised stripes on the surface of the outer sheath. After extrusion, it is cooled and shaped, and the thickness, appearance quality, and flame-retardant properties of the outer sheath are inspected.

[0043] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the inventive spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A cable for new energy vehicles, comprising an innermost conductor layer (1), the conductor layer (1) being formed by stranding multiple tin-plated copper wires, characterized in that: The conductor layer (1) is covered with a first insulating layer (2), an inner shielding layer (3) is fixedly provided on the outside of the first insulating layer (2), a second insulating layer (4) is fixedly provided on the outside of the inner shielding layer (3), an outer shielding layer (5) is fixedly provided on the outside of the second insulating layer (4), a heat dissipation layer (6) is fixedly provided on the outside of the outer shielding layer (5), and an outer sheath (7) is fixedly provided on the outside of the heat dissipation layer (6).

2. The cable for new energy vehicles according to claim 1, characterized in that: The first insulating layer (2) is made of cross-linked polyethylene material.

3. The cable for new energy vehicles according to claim 1, characterized in that: The inner shielding layer (3) is a woven copper wire mesh structure.

4. The cable for new energy vehicles according to claim 1, characterized in that: The second insulating layer (4) is made of silicone rubber and ceramic particles.

5. A cable for new energy vehicles according to claim 1, characterized in that: The heat dissipation layer (6) is composed of a spirally wound metal wire and a thermally conductive silicone composite, wherein the metal wire is a nickel-plated copper wire.

6. A new energy vehicle cable according to claim 1, characterized in that: The outer sheath (7) is made of flame-retardant thermoplastic polyurethane material, and the surface of the outer sheath (7) is provided with axially distributed raised stripes (8).

7. A cable for new energy vehicles according to claim 1, characterized in that: The outer shielding layer (5) is an aluminum-plastic composite tape wrapping layer.

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