Flame-retardant and wear-resistant new energy automobile high-voltage cable

Abstract

The utility model discloses a flame-retardant wear-resistant new energy automobile high-voltage cable, which comprises a cable core, the cable core is composed of a plurality of groups of wire cores, a second insulating layer and a filling layer, the filling layer is arranged in a gap between the second insulating layer and the wire cores, the wire cores are annularly distributed at equal intervals, a shielding layer is arranged outside the cable core, and the shielding layer is arranged in the gap between the second insulating layer and the wire cores. The shielding layer is arranged outside the cable core, the braid layer is arranged outside the shielding layer, the composite flame-retardant layer is arranged outside the braid layer, the composite wear-resistant layer is arranged outside the composite flame-retardant layer, the cable core is composed of a conductor and a first insulating layer, the conductor is formed by twisting multiple strands of copper wires, the first insulating layer is arranged outside the conductor in an extruded mode, and the first insulating layer is arranged outside the cable core in an extruded mode. The structure solves the problems that the cable is easy to ignite by flame and the wear resistance of the cable is not good enough.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle cable technology, specifically a flame-retardant and wear-resistant high-voltage cable for new energy vehicles. Background Technology

[0002] High-voltage cables for new energy vehicles are specifically designed for high-voltage power transmission within these vehicles. They are primarily used to connect key components such as batteries, motors, and controllers, ensuring efficient and stable power transmission. These cables typically consist of a conductor, insulation layer, shielding layer, and sheath layer. The conductor is usually made of multiple strands of fine copper wire. The insulation layer, made of high-quality insulating material, wraps around the conductor. The shielding layer is located outside the insulation layer, and the sheath layer is the outermost layer of the cable. High-voltage cables for new energy vehicles are widely used for connections between batteries and motors, between motors and controllers, and between other components requiring high-performance power transmission. Flame retardancy and wear resistance are key characteristics of these cables.

[0003] For example, Chinese patent CN219800514U, entitled "A High-Voltage Cable for New Energy Vehicles," includes a conductor, an insulation layer, a shielding layer, and a sheath layer arranged sequentially from the inside out. The conductor is composed of strands twisted in a 1+6+12 three-layer configuration, wherein the pitch ratio of the middle layer is 19-21, and the pitch ratio of the outer layer is 13-15. The strands are made of softened and annealed copper monofilaments twisted together, with a pitch ratio of 28-38, and the twisting direction of the softened and annealed copper monofilaments is the same as that of the strands. The shielding layer is composed of copper wires arranged from the inside out. The structure comprises a braided layer and an aluminum-plastic composite wrapping layer. The insulating layer is a silicone rubber layer. The copper wire diameter of the copper wire braided layer is 0.12mm-0.15mm, the braiding density of the copper wire braided layer is ≥85%, and the wrapping overlap rate of the copper wire braided layer is ≥20%. The aluminum-plastic composite wrapping layer is made of aluminum-plastic composite tape with a width of 25mm and a thickness of 0.025mm. The wrapping overlap rate of the aluminum-plastic composite wrapping layer is ≥20%. The outer surface of the copper wires in the copper wire braided layer is coated with a tin-plated layer.

[0004] While the existing technologies mentioned above can enable the use of cables in new energy vehicles, in practical applications, the cables are easily ignited by flames. Typically, after a collision, the battery of a new energy vehicle is prone to combustion, which can ignite the internal cables, increasing the risk of fire. On the other hand, the cables do not have good wear resistance. During driving, the cables rub against the vehicle frame after bumps, causing them to break due to long-term wear, thus increasing the risk of short circuits and leakage. Therefore, they do not meet current requirements. To address this, we propose a flame-retardant and wear-resistant high-voltage cable for new energy vehicles. Utility Model Content

[0005] The purpose of this invention is to provide a flame-retardant and wear-resistant high-voltage cable for new energy vehicles, in order to solve the problems mentioned in the background art, such as the cable being easily ignited by flames and the cable's insufficient wear resistance.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a flame-retardant and wear-resistant high-voltage cable for new energy vehicles, comprising a cable core, wherein the cable core is composed of multiple sets of wire cores, a second insulation layer and a filling layer, the filling layer is disposed in the gap between the second insulation layer and the wire cores, and the wire cores are distributed in a ring at equal intervals, a shielding layer is disposed outside the cable core, a braided layer is disposed outside the shielding layer, a composite flame-retardant layer is disposed outside the braided layer, and a composite wear-resistant layer is disposed outside the composite flame-retardant layer.

[0007] Preferably, the wire core consists of a conductor and a first insulating layer, wherein the conductor is composed of multiple strands of copper wire twisted together, and the first insulating layer is extruded onto the outside of the conductor.

[0008] Preferably, the filling layer is provided with reinforcing ribs inside, and the reinforcing ribs are inserted into the filling layer.

[0009] Preferably, the composite flame-retardant layer consists of a flame-retardant outer layer, a flame-retardant reinforcing layer, and a flame-retardant inner layer. The flame-retardant inner layer is extruded and disposed outside the braided layer, the flame-retardant reinforcing layer is extruded and disposed outside the flame-retardant inner layer, and the flame-retardant outer layer is extruded and disposed outside the flame-retardant reinforcing layer.

[0010] Preferably, the composite wear-resistant layer consists of a wear-resistant outer layer, a wear-resistant reinforcing layer, and a wear-resistant base layer. The wear-resistant base layer is coated on the outside of the flame-retardant outer layer, the wear-resistant reinforcing layer is sprayed on the outside of the wear-resistant base layer, and the wear-resistant outer layer is extruded onto the outside of the wear-resistant reinforcing layer.

[0011] Preferably, the braided layer is wrapped around the outside of the shielding layer, and the braided layer is woven from multiple strands of tin-plated copper wire.

[0012] Preferably, the shielding layer is made of conductive PVC material, and the shielding layer is extruded onto the outside of the second insulating layer.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] (1) The present invention can prevent the cable from being ignited by flames by setting a composite flame-retardant layer. The fireproof outer layer can effectively prevent the spread and burning of flames, thereby protecting the integrity and functionality of the cable. At the same time, the fireproof outer layer can significantly reduce the burning speed of the cable in a fire, buying valuable time for personnel evacuation and fire fighting. Moisture intrusion into the cable may cause the insulation layer to become damp, which may lead to short circuits and leakage. The fireproof reinforcement layer can effectively isolate moisture and prevent this from happening, ensuring the safety and stability of the electrical system. During the operation of new energy vehicles, components such as batteries and motors will generate high heat. The fireproof inner layer can prevent this heat from being directly conducted to the cable, preventing the cable from being damaged by high temperature and ensuring the normal operation of the electrical system.

[0015] (2) By setting a composite wear-resistant layer, this utility model can improve the wear resistance of the cable. During the operation of new energy vehicles, high-voltage cables may rub against other parts of the vehicle and road vibrations. The presence of the wear-resistant outer layer can significantly reduce the damage of such friction to the cable sheath, thereby extending the overall service life of the cable. At the same time, it can prevent electrical faults such as leakage and short circuit caused by cable damage. During the operation of new energy vehicles, high-voltage cables may come into contact with various chemical substances, such as acid rain and oil. The wear-resistant reinforcement layer can isolate the contact between chemical substances and the inside of the cable, prevent chemical corrosion, and thus extend the service life of the cable. The car engine compartment is connected to the external environment, and insects may enter the engine compartment to bite or damage the cable, causing damage to the cable insulation layer and thus causing electrical faults such as leakage and short circuit. Setting a wear-resistant base layer can effectively prevent insects from approaching and damaging the cable and protect the integrity of the cable.

[0016] (3) This utility model can improve the bending resistance of the cable through the reinforcing ribs and braided layer. The reinforcing ribs can enhance the cable's ability to withstand tension and reduce the risk of breakage caused by external force. At the same time, the reinforcing ribs can enhance the overall rigidity of the cable and prevent the cable from deforming due to uneven force during use. The braided layer can effectively shield external electromagnetic interference and protect the internal signal of the cable from being affected. At the same time, the braided layer can resist external physical impact and cutting and protect the internal structure of the cable from damage. Attached Figure Description

[0017] Figure 1 This is a perspective view of the overall structure of this utility model;

[0018] Figure 2 This is a cross-sectional view of the internal structure of this utility model;

[0019] Figure 3 This is a partial enlarged view of the interior of the composite flame-retardant layer of this utility model;

[0020] Figure 4 This is a magnified view of the interior of the composite wear-resistant layer of this utility model.

[0021] In the diagram: 1. Cable core; 2. Wire core; 3. Conductor; 4. First insulation layer; 5. Filler layer; 6. Second insulation layer; 7. Shielding layer; 8. Braided layer; 9. Composite flame-retardant layer; 901. Flame-retardant outer layer; 902. Flame-retardant reinforcing layer; 903. Flame-retardant inner layer; 10. Composite wear-resistant layer; 1001. Wear-resistant outer layer; 1002. Wear-resistant reinforcing layer; 1003. Wear-resistant base layer; 11. Reinforcing rib. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0023] Please see Figure 1-4 This utility model provides an embodiment of a flame-retardant and wear-resistant high-voltage cable for new energy vehicles, comprising a cable core 1, which is composed of multiple sets of wire cores 2, a second insulation layer 6, and a filling layer 5. The filling layer 5 is disposed in the gap between the second insulation layer 6 and the wire cores 2, and the wire cores 2 are distributed in a ring at equal intervals. A shielding layer 7 is disposed outside the cable core 1, a braided layer 8 is disposed outside the shielding layer 7, a composite flame-retardant layer 9 is disposed outside the braided layer 8, and a composite wear-resistant layer 10 is disposed outside the composite flame-retardant layer 9. The wire core 2 is composed of a conductor 3 and a first insulation layer 4. The conductor 3 is composed of multiple strands of copper wire twisted together. The first insulation layer 4 is extruded and disposed outside the conductor 3. The shielding layer 7 is made of conductive PVC material and is extruded and disposed outside the second insulation layer 6. Both the second insulation layer 6 and the first insulation layer 4 are made of low-smoke halogen-free flame-retardant thermoplastic polyurethane elastomer material.

[0024] Please see Figure 1 and Figure 2 The filling layer 5 has a reinforcing rib 11 inside, which is inserted into the filling layer 5. The braided layer 8 is wrapped around the outside of the shielding layer 7 and is made of multiple strands of tin-plated copper wire. The filling layer 5 is made of alkali-free glass yarn, and the reinforcing rib 11 is made of rubber material, which facilitates the improvement of the cable's bending resistance through the filling layer 5 and the braided layer 8.

[0025] Please see Figure 2 and Figure 3The composite flame-retardant layer 9 consists of a flame-retardant outer layer 901, a flame-retardant reinforcing layer 902, and a flame-retardant inner layer 903. The flame-retardant inner layer 903 is extruded and disposed outside the braided layer 8, the flame-retardant reinforcing layer 902 is extruded and disposed outside the flame-retardant inner layer 903, and the flame-retardant outer layer 901 is extruded and disposed outside the flame-retardant reinforcing layer 902. The flame-retardant outer layer 901 is made of low-smoke halogen-free flame-retardant polyolefin material, the flame-retardant reinforcing layer 902 is made of polytetrafluoroethylene material, and the flame-retardant inner layer 903 is made of crushed rock wool mixed with resin, which facilitates the improvement of the fire resistance of the cable through the composite flame-retardant layer 9.

[0026] Please see Figure 2 and Figure 4 The composite wear-resistant layer 10 consists of a wear-resistant outer layer 1001, a wear-resistant reinforcing layer 1002, and a wear-resistant base layer 1003. The wear-resistant base layer 1003 is coated on the outside of the flame-retardant outer layer 901, the wear-resistant reinforcing layer 1002 is sprayed on the outside of the wear-resistant base layer 1003, and the wear-resistant outer layer 1001 is extruded on the outside of the wear-resistant reinforcing layer 1002. The wear-resistant outer layer 1001 is made of nylon resin, the wear-resistant reinforcing layer 1002 is made of fluorocarbon coating, and the wear-resistant base layer 1003 is made of bifenthrin. This composite wear-resistant layer 10 facilitates the improvement of the cable's wear resistance.

[0027] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A flame-retardant and wear-resistant high-voltage cable for new energy vehicles, comprising a cable core (1), characterized in that: The cable core (1) is composed of multiple sets of wire cores (2), a second insulation layer (6) and a filling layer (5). The filling layer (5) is disposed in the gap between the second insulation layer (6) and the wire cores (2), and the wire cores (2) are distributed in a ring at equal intervals. The cable core (1) is provided with a shielding layer (7) on the outside, a braided layer (8) is provided on the outside of the shielding layer (7), a composite flame-retardant layer (9) is provided on the outside of the braided layer (8), and a composite wear-resistant layer (10) is provided on the outside of the composite flame-retardant layer (9).

2. The flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 1, characterized in that: The core (2) is composed of a conductor (3) and a first insulation layer (4). The conductor (3) is composed of multiple strands of copper wire twisted together, and the first insulation layer (4) is extruded and disposed on the outside of the conductor (3).

3. The flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 2, characterized in that: The filling layer (5) is provided with reinforcing ribs (11), which are inserted into the filling layer (5).

4. The flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 3, characterized in that: The composite flame-retardant layer (9) is composed of a flame-retardant outer layer (901), a flame-retardant reinforcing layer (902), and a flame-retardant inner layer (903). The flame-retardant inner layer (903) is extruded and disposed outside the braided layer (8). The flame-retardant reinforcing layer (902) is extruded and disposed outside the flame-retardant inner layer (903). The flame-retardant outer layer (901) is extruded and disposed outside the flame-retardant reinforcing layer (902).

5. The flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 4, characterized in that: The composite wear-resistant layer (10) consists of a wear-resistant outer layer (1001), a wear-resistant reinforcing layer (1002), and a wear-resistant base layer (1003). The wear-resistant base layer (1003) is coated on the outside of the flame-retardant outer layer (901), the wear-resistant reinforcing layer (1002) is sprayed on the outside of the wear-resistant base layer (1003), and the wear-resistant outer layer (1001) is extruded onto the outside of the wear-resistant reinforcing layer (1002).

6. The flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 5, characterized in that: The braided layer (8) is wrapped around the outside of the shielding layer (7), and the braided layer (8) is woven from multiple strands of tin-plated copper wire.

7. A flame-retardant and wear-resistant high-voltage cable for new energy vehicles according to claim 6, characterized in that: The shielding layer (7) is made of conductive PVC material, and the shielding layer (7) is extruded and disposed outside the second insulating layer (6).

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