A battery cable for road vehicles

Abstract

This utility model relates to the field of cable technology, and in particular to a battery cable for road vehicles. From the outside in, it comprises an outer sheath, an aluminum foil shielding layer, an inner sheath, and a cable. The cable includes four sets of power supply cables and three sets of communication cables. The four sets of power supply cables are symmetrically arranged in two parallel groups on the left and right sides within the inner sheath. The three sets of communication cables are arranged in parallel from top to bottom between the two parallel power supply cable groups. Both the communication cable in the middle and the four sets of power supply cables are covered with an aluminum foil shielding layer. This utility model cable features low conductivity loss, high electrical strength, high anti-interference ability, and high flame retardancy, protective wear resistance, and other characteristics.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to a battery cable for road vehicles. Background Technology

[0002] In the design and manufacturing process of battery cables for road vehicles, it is essential to ensure high dielectric strength, interference resistance, flame retardancy, and abrasion resistance. However, current cable technology generally cannot simultaneously meet all of these requirements. Especially in complex road environments, cables must withstand various mechanical stresses, electromagnetic interference, and high temperatures. Existing cable designs often have shortcomings in certain performance aspects, resulting in overall performance falling short of expectations. For example, some cables may perform well in interference resistance but lack abrasion resistance and high-temperature resistance; while others may excel in flame retardancy but fail to meet requirements for electromagnetic interference resistance and dielectric strength. Therefore, there is an urgent need for battery cables for road vehicles that can comprehensively improve dielectric strength, interference resistance, flame retardancy, abrasion resistance, and high-temperature resistance to meet the demands of complex and ever-changing road environments. Existing technologies urgently need improvement to address these issues. Utility Model Content

[0003] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a battery cable for road vehicles.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a battery cable for road vehicles, comprising, from the outside to the inside, an outer sheath, an aluminum foil shielding layer, an inner sheath, and a cable. The cable includes four sets of power supply cables and three sets of communication cables. The four sets of power supply cables are symmetrically arranged in two parallel groups on the left and right sides within the inner sheath. The three sets of communication cables are arranged in parallel from top to bottom between the two parallel power supply cable groups. The communication cable located in the middle and the four sets of power supply cables are both covered with an aluminum foil shielding layer.

[0005] In some embodiments, the power supply cable and the communication cable are both composed of four-core wires, and each wire is provided with an insulation layer.

[0006] In some embodiments, the outer insulation layer of the four-core conductors is of a different color.

[0007] In some embodiments, the power supply cable includes, from the outside to the inside, an aluminum foil shielding layer, a braided mesh layer, and a power supply conductor.

[0008] In some embodiments, the woven mesh layer is a tin-plated copper woven mesh.

[0009] In some embodiments, the outer sheath is made of a wear-resistant material.

[0010] In some embodiments, the inner sheath is made of a high-temperature resistant material.

[0011] Compared with the prior art, the beneficial effects of this utility model are: by using the stacked structure of outer sheath, aluminum foil shielding layer, inner sheath and cable, combined with the symmetrical arrangement of power supply cable groups and the communication cable layout in the middle, and using aluminum foil shielding layer to cover key cables, the problem that existing cables cannot simultaneously meet the requirements of electrical strength, anti-interference, wear resistance and high temperature resistance is solved. It has the advantages of comprehensively improving electrical strength, anti-interference ability, flame retardant performance, protective wear resistance and high temperature resistance.

[0012] Details of one or more embodiments of this application are set forth in the following drawings and description to make other features, objects and advantages of this application more readily apparent. The embodiments of this application will provide a detailed description and understanding of the application. Attached Figure Description

[0013] Figure 1 This is a cross-sectional view of the cable of this utility model;

[0014] Figure 2 This is a cross-sectional view of the power supply cable.

[0015] In the diagram: 1. Outer sheath; 2. Aluminum foil shielding layer; 3. Inner sheath; 4. Power supply cable; 5. Communication cable; 6. Aluminum foil shielding layer; 7. Braided mesh layer; 8. Power supply conductor. Detailed Implementation

[0016] 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.

[0017] In traditional road vehicle battery cables, the distribution structure of power supply cables and communication cables lacks reasonable electromagnetic compatibility design, leading to increased crosstalk between different cables; uneven mechanical stress distribution between cable groups affects overall vibration resistance; and the combination of shielding layer and sheath material cannot simultaneously meet the requirements of high-frequency electromagnetic noise suppression and physical protection. For example, in the power battery system of hybrid or pure electric vehicles, power supply cables need to carry kilowatt-level high currents, while communication cables need to transmit millivolt-level weak signals. When the two are arranged in a disordered cross pattern, the alternating magnetic field generated by the power supply cables will induce common-mode noise in the communication cables, causing the signal acquisition error of the battery management system to exceed the ±5% threshold; the relative displacement of the cable group due to vibration during vehicle operation will cause local wear of the insulation layer, resulting in nonlinear changes in the distributed capacitance between the lines; and the outer sheath material is not designed with a multi-layer composite structure to withstand road gravel impact and oil corrosion, causing the tear resistance to drop below the critical value.

[0018] If the above problems are not resolved, electromagnetic interference inside the cable will directly cause the battery state of charge estimation deviation to exceed the safety threshold, triggering the system protection mechanism and limiting power output; the accumulation of insulation wear may cause inter-wire arc discharge, resulting in the risk of thermal runaway of the battery module; damage to the outer sheath will accelerate the oxidation of the internal metal shielding layer, increasing the shielding effectiveness decay rate to more than 3 times that under normal operating conditions, ultimately causing the failure rate of the vehicle power system to rise to an unacceptable level.

[0019] To address the aforementioned issues, this application first analyzes the causes of electromagnetic interference resulting from the disordered cross-arrangement of power supply and communication cables. It finds that the coupling path of the alternating magnetic field generated by high-current power supply cables to low-voltage signal cables is a key factor. Based on the distribution patterns of electromagnetic fields, an attempt is made to arrange power supply cables symmetrically in groups to create a layout where magnetic fields cancel each other out. Simultaneously, communication cables are placed in the middle region between the two groups of power supply cables to utilize the low-interference zone of the symmetrical field distribution. Regarding the mechanical stress problem caused by cable vibration, the effects of different cable arrangements on the dispersion of bending stress are studied. It is found that symmetrically arranged power supply cable groups can form a mechanically balanced structure, while the parallel stacking of communication cables can reduce relative displacement. Addressing the contradiction between shielding effectiveness and protection requirements, the attenuation characteristics of single-layer and multi-layer shielding are tested, confirming that setting separate shielding layers for power supply and communication cables can more effectively suppress high-frequency noise transmission.

[0020] In this regard, such as Figure 1-2As shown, this application proposes a battery cable for road vehicles, which includes, from the outside to the inside, an outer sheath 1, an aluminum foil shielding layer 62, an inner sheath 3, and a cable. The cable includes four sets of power supply cables 4 and three sets of communication cables 5. The four sets of power supply cables 4 are divided into two groups of parallel power supply cables 4 arranged symmetrically on the left and right sides within the inner sheath 3. The three sets of communication cables 5 are arranged in parallel from top to bottom between the two groups of parallel power supply cables 4. The communication cable 5 located in the middle and the four sets of power supply cables 4 are both covered with an aluminum foil shielding layer 62.

[0021] The outer sheath 1 refers to the outermost protective structure, which can be made of high-density polyethylene or polyurethane. It resists external mechanical wear and environmental corrosion, improving cable durability. The aluminum foil shielding layer 62 is an electromagnetic shielding layer made of aluminum, which can be achieved by wrapping or longitudinally wrapping with aluminum foil. It effectively isolates external electromagnetic interference and prevents internal signal leakage. The inner sheath 3 is an insulating protective layer located inside the aluminum foil shielding layer 62. It can be made of silicone rubber or fluoroplastics, which can withstand high temperatures and maintain the stability of the internal cable structure. The symmetrical arrangement of the four power supply cables (4 groups) means dividing the four power supply cables (4) into two groups arranged horizontally and vertically. This can be achieved by layered twisting or fixed brackets, balancing current distribution and optimizing space utilization. The parallel arrangement of the communication cables (5) means placing three communication cables (5) sequentially and parallel between the two power supply cable groups (4). This can be achieved by spaced arrangement or independent channel design, reducing signal crosstalk between different cables and improving transmission stability.

[0022] The core innovation of this application lies in the symmetrical layout of the four power supply cables and the centrally parallel arrangement of the communication cable 5, combined with the inner and outer aluminum foil shielding layers 62 and the high-temperature and wear-resistant sheath, to achieve balanced current distribution, improved anti-interference capability and enhanced protection performance within a limited space, thereby comprehensively solving multiple technical requirements such as high electrical strength, anti-interference and wear resistance and flame retardancy.

[0023] The working process and principle of this application are as follows: the battery cable for road vehicles, from the outside to the inside, includes an outer sheath 1, an aluminum foil shielding layer 62, an inner sheath 3, and the cable itself. The cable includes four sets of power supply cables 4 and three sets of communication cables 5. The four sets of power supply cables 4 are symmetrically arranged in two parallel groups (left and right) within the inner sheath 3, forming a mechanically balanced structure and reducing mechanical stress caused by vibration. The three sets of communication cables 5 are arranged in parallel from top to bottom between the two sets of parallel power supply cables 4, utilizing the low-interference zone of the symmetrical field distribution to reduce electromagnetic interference. The communication cables 5 located in the middle and the four sets of power supply cables 4 are both covered with aluminum foil shielding layers 62 to further suppress high-frequency noise transmission. The outer sheath 1 provides physical protection, the inner sheath 3 serves as insulation and separation, and the overall aluminum foil shielding layer 62 provides comprehensive electromagnetic shielding.

[0024] This structural design uses the symmetrical arrangement of the power supply cables 4 to create mutually canceling magnetic fields, reducing electromagnetic interference to the communication cable 5. The communication cable 5 is placed in a low-interference area between the power supply cables 4, further reducing interference. Independent shielding layers are provided for both the power supply cables 4 and the intermediate communication cable 5, effectively isolating electromagnetic interference between different types of cables. The overall symmetry and parallel arrangement of the structure help to evenly distribute mechanical stress and improve vibration resistance. The multi-layered structural design addresses both electromagnetic shielding and physical protection requirements.

[0025] As a preferred embodiment, the solution of this application is specifically implemented as follows:

[0026] The battery cable for road vehicles has an outer sheath 1 made of wear-resistant material, beneath which is an aluminum foil shielding layer 62. The inner sheath 3 is made of high-temperature resistant material and is located inside the aluminum foil shielding layer 62. The cable includes four sets of power supply cables 4 and three sets of communication cables 5, all composed of four-core conductors, with each conductor having an external insulation layer.

[0027] The four power supply cables 4 are divided into two groups, left and right, within the inner sheath 3, with each group arranged vertically in parallel. The two groups of power supply cables 4 are symmetrically arranged. Each group of power supply cables 4, from the outside to the inside, includes an aluminum foil shielding layer 62, a tinned copper braided mesh layer 7, and a power supply conductor 8.

[0028] Three sets of communication cables 5 are located between two sets of parallel power supply cables 4, arranged in parallel order from top to bottom. The communication cable 5 located in the middle is covered with an independent aluminum foil shielding layer 62.

[0029] The outer insulation layers of the four-core conductors are different colors for easy identification. The overall structure optimizes electromagnetic compatibility and mechanical stability through multi-layer shielding and symmetrical arrangement.

[0030] Through the above solution, this application effectively solves the electromagnetic interference problem between the power supply cable 4 and the communication cable 5 in traditional road vehicle battery cables. The symmetrically arranged power supply cables 4 form mutually canceling magnetic fields, reducing the impact on the communication cable 5. The communication cable 5 is placed in a low-interference area, further reducing interference. The independent shielding layer effectively isolates electromagnetic interference between different types of cables. The symmetry and parallel arrangement of the overall structure improve vibration resistance and reduce the risk of insulation wear. The multi-layer structure design takes into account both electromagnetic shielding and physical protection requirements, improving the cable's durability and reliability. This optimized design significantly improves the electromagnetic compatibility, mechanical stability, and overall performance of road vehicle battery cables.

[0031] In some of the solutions described above in this application, the conductors of the power supply cable 4 and the communication cable 5 are not provided with independent insulation layers, which poses a risk of short circuit between conductors. Furthermore, there is a lack of differentiated design for cables with different functions, making it difficult to meet the stable operation requirements in complex electromagnetic environments.

[0032] This application further proposes that both the power supply cable 4 and the communication cable 5 are composed of four-core conductors, and each conductor is provided with an insulation layer.

[0033] The four-core cable assembly consists of four independent conductors forming a cable unit. Each conductor is covered with an insulating layer, which encloses the conductor. The four-core assembly forms a power supply or communication unit. The conductors are physically isolated from each other through the insulating layer, preventing direct contact and short circuits. This four-core structure provides redundant conductive paths, allowing the cable to maintain function even if a single conductor fails.

[0034] Specifically, the power supply cable 4 and the communication cable 5 each consist of four independent conductors, each wrapped with an insulation layer. The four conductors are twisted or arranged side-by-side to form a cable unit. The insulation material can be polyvinyl chloride or cross-linked polyethylene, with a thickness controlled within the range of 0.3-0.5 mm. The conductors are made of copper or aluminum alloy, with a cross-sectional area of ​​1.5-4.0 square millimeters. When transmitting electrical energy or signals, the four-core conductor combination can distribute the current or signal load through multiple paths, reducing the risk of overload on a single conductor. The insulation layer prevents contact between conductors, avoiding short circuits caused by conductor exposure due to friction or vibration. The four-core structure also facilitates the differentiation of conductor polarity or function through color markings during installation, improving assembly efficiency.

[0035] As a preferred embodiment, the solution of this application is implemented as follows: Both the power supply cable 4 and the communication cable 5 are composed of four-core wires. Each wire is provided with an insulation layer. Specifically, the four-core wire includes four parallel wires, each wire being covered with an insulating material. The insulation layer can be made of materials such as polyvinyl chloride, polyethylene, or cross-linked polyethylene to ensure electrical isolation between the wires. Furthermore, the four wires can be combined together by twisting or paralleling to form an integral cable structure.

[0036] Through the above technical solution, this application achieves effective insulation between the power supply cable 4 and the communication cable 5. This provides excellent electrical isolation between the various conductors of the cable, effectively preventing short circuits and leakage. Furthermore, the four-core conductor structure improves the cable's transmission capacity and stability, enabling it to meet the power supply and communication requirements of road vehicle batteries. Specifically, the four-core structure increases the cable's load-bearing capacity while improving the reliability of signal transmission. For example, in the power supply cable 4, the four cores can be used for the positive, negative, ground, and backup terminals respectively, while in the communication cable 5, they can be used to transmit different signals or data. This structural design gives the cable greater flexibility and adaptability, meeting the needs of different vehicles and battery systems.

[0037] In some of the solutions described above in this application, the external insulation layers of the power supply cable 4 and communication cable 5, which are composed of four-core conductors, lack distinguishing markings, making it difficult to quickly identify the function of each conductor during installation and maintenance, which may lead to wiring errors or reduced maintenance efficiency.

[0038] This application further proposes that the external insulation layers of the four-core conductors are all different colors.

[0039] In this four-core cable, each conductor's insulation layer is distinguished by a different color. The color difference is achieved by using different color masterbatches in the insulation material; for example, red, yellow, blue, and green correspond to the four conductors respectively. The color settings form a fixed correspondence with the conductor's electrical parameters or function; for example, the red conductor is used for positive current transmission, and the blue conductor is used for the negative circuit. This color differentiation feature complements the symmetrical grouping structure of the four groups of power supply cables, allowing for identification by end color even under the aluminum foil shielding layer 62 and the braided mesh layer 7.

[0040] Specifically, during cable assembly, operators can accurately complete cable end connections based on color-coding. When troubleshooting is required, maintenance personnel can determine the conductor's function by observing the insulation color after peeling off the inner sheath 3, without the need for additional testing equipment. Color differentiation, while maintaining the original insulation performance, directly improves installation accuracy through visual identification, reducing the risk of short circuits due to misconnections. Different colored insulation layers and the aluminum foil shielding layer 62 form physical isolation, preventing interference from contact between the color-coded layer and the conductive layer. This solution achieves rapid identification of complex cable structures through a color coding system, maintaining the effectiveness of markings in multi-layered shielding structures.

[0041] As a preferred embodiment, the solution of this application is implemented as follows: the outer insulation layers of the four-core wires are all different colors. Specifically, the outer insulation layer of the first wire is red, the outer insulation layer of the second wire is blue, the outer insulation layer of the third wire is yellow, and the outer insulation layer of the fourth wire is green. This color configuration can be applied to the four-core wires in power supply cables 4 and communication cables 5.

[0042] Through the above technical solution, this application achieves rapid identification and differentiation of different conductors in battery cables for road vehicles. Therefore, during cable installation, maintenance, or troubleshooting, technicians can quickly identify the function and purpose of each conductor, reducing the possibility of wiring errors and improving work efficiency. Furthermore, this color-coding method helps standardize cable production and usage processes, facilitating communication and collaboration between different manufacturers and users.

[0043] In some of the solutions described above in this application, although the power supply cable 4 composed of four-core wires can be distinguished by color and has an insulation layer, in actual use, the insulation layer of the four-core wires cannot effectively cope with electromagnetic interference and mechanical stress, resulting in insufficient anti-interference ability and durability.

[0044] This application further proposes that the power supply cable 4 includes, from the outside to the inside, an aluminum foil shielding layer 62, a braided mesh layer 7, and a power supply conductor 8.

[0045] The aluminum foil shielding layer 62 wraps around the braided mesh layer 7 to block external electromagnetic interference. The braided mesh layer 7, made of woven metal wire, covers the power supply conductor 8 to provide mechanical protection and grounding. The power supply conductor 8 is composed of four independent insulated conductors with different colored insulation layers. The aluminum foil shielding layer 62 and the braided mesh layer 7 are fixed together by interlayer adhesive, and the braided mesh layer 7 and the power supply conductor 8 are isolated by filler material. For example, the braided mesh layer 7 is woven from 0.1 mm diameter tinned copper wire with 90% coverage, and the aluminum foil shielding layer 62 is 0.05 mm thick.

[0046] Specifically, the aluminum foil shielding layer 62, as the outermost layer, completely isolates external electromagnetic interference signals from intruding into the power supply conductors 8. The braided mesh layer 7, located inside the aluminum foil shielding layer 62, disperses external compressive or bending stress through its metal wire braiding structure, while also serving as a grounding layer to conduct internal charges. The four power supply conductors 8 are wrapped by the braided mesh layer 7, with independent insulation layers preventing short circuits between conductors. The aluminum foil shielding layer 62 and the braided mesh layer 7, when stacked, form a double shielding structure, reducing signal attenuation in the complex electromagnetic environment of a vehicle. The high coverage metal wire structure of the braided mesh layer 7 can withstand frequent vibration and friction, preventing insulation failure of the cables due to mechanical damage. The color-differentiated design of the four conductors facilitates polarity differentiation during installation, further reducing the risk of wiring errors.

[0047] As a preferred embodiment, the solution of this application is implemented as follows: The power supply cable 4 comprises, from the outside to the inside, an aluminum foil shielding layer 62, a braided mesh layer 7, and a power supply conductor 8. The aluminum foil shielding layer 62 can be made of aluminum foil with a thickness of 0.1 mm, the braided mesh layer 7 can be made of tin-plated copper wire, and the power supply conductor 8 can be made of copper core wire with a cross-sectional area of ​​35 mm². The aluminum foil shielding layer 62 is fixed to the outside of the braided mesh layer 7 by wrapping it with insulating tape, and the braided mesh layer 7 is tightly wrapped around the outside of the power supply conductor 8 by an extrusion process. This multi-layer structure design can effectively improve the electromagnetic shielding performance of the power supply cable 4.

[0048] Through the above technical solution, this application achieves a multi-layer shielding structure for the power supply cable 4, improving the cable's resistance to electromagnetic interference. The aluminum foil shielding layer 62 effectively blocks external electromagnetic wave interference, while the braided mesh layer 7 further enhances the shielding effect and improves the cable's mechanical strength. This structural design enables the power supply cable 4 to maintain stable and reliable power supply performance in the complex electromagnetic environment of a vehicle, reducing the impact of electromagnetic interference on the vehicle's electronic systems.

[0049] In some of the solutions described above in this application, tin-plated copper braided wire mesh is at risk of decreased conductivity, insufficient corrosion resistance, and weakened mechanical strength during long-term use.

[0050] This application further proposes that the 7th braided mesh layer is a tin-plated copper braided mesh.

[0051] The tin-plated copper braided mesh is made of tin-plated copper wire woven into a ring-shaped wrapping structure, with the tin plating thickness controlled within the range of 0.5-2 micrometers. The diameter of a single tin-plated copper wire can be selected from 0.08-0.15 mm, the weaving angle is controlled within 30-45 degrees, and the weaving density reaches 85%-95%. The tin plating layer forms a metallurgical bonding layer with the copper substrate, and the weaving structure creates interlaced support between the wires.

[0052] Specifically, tin-plated copper braided wire mesh uses a layer of metallic tin to cover the surface of the copper substrate, forming a physical barrier that prevents oxygen from contacting the copper base. Under cable bending conditions, the tin-plated copper wires absorb mechanical stress through the elastic deformation of the braided structure, and the cross-contact at the braided joints maintains a continuous conductive path. The tin plating forms a dense oxide film at high temperatures, inhibiting further oxidation and corrosion of the copper substrate. For example, in a continuous operating environment at 150°C, the conductivity retention rate of tin-plated copper braided wire mesh can reach over 95%, while ordinary copper braided wire mesh can only maintain 82%. This structure maintains electromagnetic shielding performance while reducing contact resistance to below 1.5 μΩ·m through tin plating, approximately 30% lower than unplated copper braided wire mesh.

[0053] As a preferred embodiment, the solution of this application is implemented as follows: The braided mesh layer 7 is made of tin-plated copper braided mesh. The tin-plated copper braided mesh is formed by interlacing multiple tin-plated copper wires to form a mesh structure. The diameter of the tin-plated copper wires can be selected between 0.10 mm and 0.15 mm. The braiding density of the braided mesh layer 7 can be set between 80% and 95%. The tin-plated copper braided mesh layer 7 covers the outside of the power supply conductor 8, forming a double shielding structure between it and the aluminum foil shielding layer 62.

[0054] Through the above technical solution, this application improves the electromagnetic shielding performance of the cable. The tin-plated copper braided mesh layer 7 and the aluminum foil shielding layer 62 work together to form a more complete electromagnetic shielding structure. The tin-plated copper braided mesh has good conductivity and flexibility, which can effectively block external electromagnetic interference while maintaining the cable's flexibility. In addition, the tin plating treatment enhances the oxidation resistance of the copper wire and extends the cable's service life.

[0055] In some of the solutions described above in this application, the outer sheath 1 needs to meet the protection requirements of road vehicles. However, conventional materials are prone to surface wear under long-term mechanical friction and complex road conditions, which leads to exposure of the internal structure and reduces the overall protection performance of the cable.

[0056] This application further proposes that the outer sheath 1 is made of a wear-resistant material.

[0057] The wear-resistant material can be polyurethane, nylon, or polyamide. Polyurethane has a Shore hardness range of 85D to 95D, and nylon has a tensile strength of not less than 60 MPa. The surface of the wear-resistant material is embossed to form a continuous raised and recessed texture, with the texture depth controlled between 0.3 mm and 0.8 mm. Silicon carbide particles are added to the material as a reinforcing phase, with a particle size distribution of 20 μm to 50 μm and a volume percentage of 5% to 8%.

[0058] Specifically, the outer sheath 1 resists friction between the vehicle chassis and the ground through a high-hardness, wear-resistant substrate, and its surface texture design disperses stress concentration areas. Silicon carbide particles form microscopic hard support points; when scratched by external objects, the particles preferentially absorb the impact and delay substrate wear. During vehicle operation, the linear wear rate of the outer sheath 1 is less than 0.1 mm / 1000 km, ensuring that the aluminum foil shielding layer 62 and the cable assembly maintain complete encapsulation over a five-year service life. The cross-linking density between the material's molecular chains reaches 3 × 10^4 mol / m³, forming a dense surface layer after high-temperature extrusion molding, preventing wear cracks from propagating inward.

[0059] As a preferred embodiment, the solution of this application is implemented as follows: the outer sheath 1 is made of abrasion-resistant material. Specifically, the outer sheath 1 can be made of polymer materials with excellent abrasion resistance, such as polyvinyl chloride (PVC), polyethylene (PE), or polyurethane (PU). For example, the outer sheath 1 can be made of polyurethane material with a Shore hardness of 90A and a thickness of 2mm. This material has excellent abrasion resistance and tear resistance, and can effectively protect the internal cable structure.

[0060] Through the above technical solution, this application improves the abrasion resistance of the cable and extends its service life. The outer sheath 1 is made of abrasion-resistant material, which can effectively resist abrasion and scratches in the road environment and protect the internal cable structure from damage. This design is suitable for the complex operating environment of road vehicles, improving the reliability and durability of the battery cable.

[0061] In some of the above-mentioned solutions in this application, the inner sheath 3, as a structural layer that wraps the power supply cable 4 and the communication cable 5, needs to withstand the heat generated during the operation of the cable and the heat conduction from the external environment. However, under long-term high-temperature conditions, ordinary materials may soften and deform, causing the aluminum foil shielding layer 62 of the internal cable to shift from the insulation layer, affecting the shielding effect and insulation performance.

[0062] This application further proposes that the inner sheath 3 is made of a high-temperature resistant material.

[0063] The high-temperature resistant material can be selected from silicone rubber, polytetrafluoroethylene, or ceramic fiber composite materials, with a long-term temperature tolerance range of -50℃ to 200℃. The high-temperature resistant material of the inner sheath 3 and the wear-resistant material of the outer sheath 1 form a composite protective layer, maintaining structural stability in high-temperature environments and preventing deformation of the inner aluminum foil shielding layer 62 due to thermal expansion. For example, when the thickness of the silicone rubber inner sheath 3 is controlled within the range of 1.2-1.8mm, it can meet the mechanical strength requirements and achieve a thermal conductivity below 0.85W / m·K.

[0064] Specifically, in high-temperature environments, the inner sheath 3 maintains the symmetrical arrangement of the power supply cables 4 and communication cables 5 through the thermal stability of the material itself. The parallel spacing between the upper and lower sets of power supply cables 4 is maintained at 3.0±0.2mm, and the vertical spacing between the three sets of communication cables 5 in the middle is maintained at 2.5±0.2mm. The high-temperature resistant material, while suppressing heat conduction, complements the metallic properties of the aluminum foil shielding layer 62. When the internal temperature of the cable reaches 150℃, the deformation of the inner sheath 3 is less than 0.3%, ensuring no relative displacement between the insulation layer of the four-core conductor and the aluminum foil shielding layer 62. This structural design allows the cable to maintain stable anti-interference capability and conductivity even in the high-temperature operating area of ​​the power battery pack.

[0065] As a preferred embodiment, the solution of this application is implemented as follows: the inner sheath 3 is made of a high-temperature resistant material. Specifically, the inner sheath 3 can be made of polytetrafluoroethylene (PTFE). PTFE has excellent high-temperature resistance and can remain stable in a temperature range of -200℃ to 260℃. Furthermore, PTFE also has good insulation and chemical stability, which can effectively protect the internal cable from the effects of high temperature and chemical corrosion.

[0066] Through the above technical solution, this application improves the high-temperature resistance of the battery cable and enhances the protection of the internal cables. As a result, the battery cable can maintain good insulation and conductivity in high-temperature environments, extending its service life and improving the reliability and safety of battery systems for road vehicles.

[0067] The above embodiments merely illustrate several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

[0068] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A battery cable for a road vehicle, characterized by: From the outside to the inside, the cable consists of an outer sheath, an aluminum foil shielding layer, an inner sheath, and cables. The cables include four sets of power supply cables and three sets of communication cables. The four sets of power supply cables are arranged symmetrically in two parallel groups on the left and right sides inside the inner sheath. The three sets of communication cables are arranged in parallel from top to bottom between the two parallel power supply cable groups. The communication cable located in the middle and the four sets of power supply cables are both covered with an aluminum foil shielding layer.

2. The battery cable for road vehicles according to claim 1, characterized in that: Both the power supply cable and the communication cable are composed of four-core conductors, and each conductor is equipped with an insulation layer.

3. A battery cable for road vehicles according to claim 2, characterized in that: The outer insulation layers of the four-core wires are all different colors.

4. A battery cable for road vehicles according to claim 3, characterized in that: The power supply cable comprises, from the outside in, an aluminum foil shielding layer, a braided mesh layer, and a power supply conductor.

5. A battery cable for road vehicles according to claim 4, characterized in that: The woven mesh layer is a tin-plated copper woven mesh.

6. A battery cable for road vehicles according to claim 1, characterized in that: The outer sheath is made of wear-resistant material.

7. A battery cable for road vehicles according to claim 1, characterized in that: The inner sheath is made of high-temperature resistant material.

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