High temperature resistant small cross section wire

Abstract

The utility model discloses a kind of high-temperature-resistant small cross-section electric wire, belong to electric wire technical field, this high-temperature-resistant small cross-section electric wire, including electric wire main body, electric wire main body includes heat-resistant electric wire, fiber bundle is set in heat-resistant electric wire inner middle part, the outside of fiber bundle is wrapped with inner ring wire and outer ring wire, the outside of inner ring wire and outer ring wire is wrapped with outer sheath;Radiating connecting mechanism, radiating connecting mechanism includes radiating connector, radiating connector includes bunching wire cylinder, bunching wire cylinder is limit connection with inner ring wire and outer ring wire, the end of bunching wire cylinder is fixedly connected with connecting plate, by fiber bundle as center, cooperate the layered stranding of 6 inner ring wires, 12 outer ring wires, form stable mechanical structure, fiber bundle provides tensile support, withstands deformation risk under high temperature, guarantees the overall form and electrical performance stability of electric wire.

Description

Technical Field

[0001] This utility model relates to the field of electrical wires, and more specifically, to a high-temperature resistant small-section electrical wire. Background Technology

[0002] In scenarios such as automotive engine compartments and high-temperature industrial equipment, small-section wires must simultaneously address challenges such as high temperatures, electromagnetic interference, mechanical stress, and heat dissipation during connections.

[0003] Existing electrical wires have shortcomings. Ordinary stranded wire structures are prone to deformation at high temperatures, lack reliable tensile support, and offer limited electromagnetic shielding, failing to adequately address both low-frequency and high-frequency interference. Furthermore, wire joints are weak points for heat dissipation; traditional joint designs are inadequate for heat dissipation, easily leading to overheating due to contact resistance, affecting signal transmission and equipment reliability. Therefore, inventing a high-temperature resistant, small-section wire to improve these problems has become a pressing issue for those skilled in the art. Utility Model Content

[0004] To overcome the above shortcomings, this utility model provides a high-temperature resistant small-section wire, which aims to improve the problems of ordinary wire stranded structure being prone to deformation at high temperatures, having a single electromagnetic shielding effect, and having difficulty in heat dissipation design of the joint.

[0005] This invention is achieved as follows: a high-temperature resistant small-section wire, comprising...

[0006] The wire body includes a heat-resistant wire, a fiber bundle is disposed in the middle of the heat-resistant wire, an inner loop wire and an outer loop wire are wrapped around the fiber bundle, and an outer sheath is wrapped around the inner loop wire and the outer loop wire.

[0007] A heat dissipation connection mechanism includes a heat dissipation connector, which includes a wire bundle, which is limitedly connected to the inner and outer ring wires, and a connecting plate is fixedly connected to the end of the wire bundle.

[0008] In a preferred embodiment of this utility model, six inner loop wires are provided, and the six inner loop wires are distributed around the outside of the fiber bundle.

[0009] In a preferred embodiment of this utility model, there are 12 outer ring wires, which are distributed around the outside of the inner ring wires.

[0010] In a preferred embodiment of this utility model, the outer loop wire is wrapped with an inner insulating layer, which is tightly wrapped around the inner loop wire, the outer loop wire, and the fiber bundle.

[0011] In a preferred embodiment of this utility model, the inner insulating layer is wrapped with an inner shielding layer, which is an aluminum foil shielding layer.

[0012] In a preferred embodiment of this utility model, the outer wall of the inner shielding layer is wrapped with an outer shielding layer, which is a copper wire braided shielding layer.

[0013] In a preferred embodiment of this utility model, the outer wall of the outer shielding layer is wrapped with an outer sheath.

[0014] In a preferred embodiment of this utility model, the outer wall of the wire bundle is provided with a merging groove, the merging groove is an isosceles trapezoid, and the inner ring wire and the outer ring wire are located in the merging groove.

[0015] In a preferred embodiment of this utility model, four sets of merging grooves are provided in a cross shape on the outer wall of the cable bundle.

[0016] In a preferred embodiment of this utility model, the outer wall of the connecting plate is evenly distributed with fins, and the fins are fixedly installed on the outer wall of the connecting plate.

[0017] The beneficial effects of this utility model are as follows: The high-temperature resistant small cross-section wire obtained by the above design has the following structural stability and high temperature resistance when in use: By using the fiber bundle as the center, combined with the layered twisting of 6 inner ring wires and 12 outer ring wires, a stable mechanical structure is formed. The fiber bundle provides tensile support, resists the risk of deformation under high temperature, and ensures the stability of the overall shape and electrical performance of the wire.

[0018] Electromagnetic shielding effect: The inner shielding layer (aluminum foil shielding layer) and the outer shielding layer (copper wire braided shielding layer) form a double-layer composite shield. The aluminum foil is used to deal with high-frequency interference, while the copper wire braiding is used to deal with low-frequency interference. The synergistic effect makes the shielding efficiency reach more than 90%, effectively isolating external electromagnetic interference and adapting to scenarios with high electromagnetic compatibility requirements, such as automotive CAN bus.

[0019] Connector heat dissipation and connection reliability: The wire bundle of the heat dissipation connector limits the inner wires and outer ring wires through the merging groove, ensuring that the wires are arranged in an orderly manner and reducing contact resistance; the fins on the outer wall of the connecting plate increase the heat dissipation area, quickly dissipate the heat of the connector, solve the potential problem of connector overheating, and improve the connection stability and service life of the wires in high-temperature environments. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a structural schematic diagram provided by an embodiment of the present utility model;

[0022] Figure 2 A schematic diagram of the disassembled structure provided for an embodiment of this utility model;

[0023] Figure 3 A schematic diagram of the end structure of the heat-resistant wire provided for an embodiment of this utility model;

[0024] Figure 4 A schematic diagram of the heat dissipation connector structure provided for an embodiment of this utility model.

[0025] In the diagram: 100 - Wire body; 110 - Heat-resistant wire; 111 - Inner loop wire; 112 - Outer loop wire; 113 - Inner insulation layer; 114 - Inner shielding layer; 115 - Outer shielding layer; 116 - Outer sheath; 117 - Fiber bundle; 200 - Heat dissipation connection mechanism; 210 - Heat dissipation connector; 211 - Wire bundle tube; 212 - Connecting plate; 213 - Fins; 214 - Merging slot. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0027] Please see Figure 1 and Figure 2 This utility model provides a technical solution: a high-temperature resistant small-section wire, comprising...

[0028] The main body of the wire 100 includes a heat-resistant wire 110, in which a fiber bundle 117 is arranged in the middle. The fiber bundle 117 is wrapped with inner loop wires 111 and outer loop wires 112. The inner loop wires 111 and outer loop wires 112 are wrapped with an outer sheath 116. The heat dissipation connection mechanism 200 includes a heat dissipation connector 210, which includes a wire bundle 211. The wire bundle 211 is limited and connected to the inner loop wires 111 and outer loop wires 112. A connecting plate 212 is fixedly connected to the end of the wire bundle 211. With the fiber bundle 117 as the center, and with the layered twisting of 6 inner loop wires 111 and 12 outer loop wires 112, a stable mechanical structure is formed. The fiber bundle 117 provides tensile support to resist the risk of deformation under high temperature and ensure the stability of the overall shape and electrical performance of the wire.

[0029] Please see Figure 3 and Figure 4 There are six inner loop wires 111, which are distributed around the outside of the fiber bundle 117. The center distance error between adjacent inner loop wires 111 is ≤ ±0.05mm. There are twelve outer loop wires 112, which are distributed around the outside of the inner loop wires 111. The space between the outer loop wires 112 and the inner loop wires 111 is filled with high-temperature resistant insulating grease with a temperature resistance range of -60℃ to +260℃.

[0030] The outer loop wire 112 is wrapped with an inner insulation layer 113. The inner insulation layer 113 is tightly wrapped around the inner loop wire 111, the outer loop wire 112, and the fiber bundle 117. The inner insulation layer 113 is made of polyimide film with an overlap rate of ≥30% and a thickness of 0.05-0.1mm. The inner insulation layer 113 is wrapped with an inner shielding layer 114. The inner shielding layer 114 is an aluminum foil shielding layer with a thickness of 0.01-0.03mm and a polyester protective film on the surface, with an overlap width of ≥3mm.

[0031] The outer wall of the inner shielding layer 114 is wrapped with an outer shielding layer 115. The outer shielding layer 115 is a copper wire braided shielding layer with copper wire diameter of 0.1-0.2mm and braiding density ≥85%. Both ends are grounded by metal ring crimping. The outer wall of the outer shielding layer 115 is wrapped with an outer sheath 116. The outer sheath 116 is made of modified polytetrafluoroethylene material with Shore hardness D50-60, temperature resistance range of -80℃ to +280℃, and thickness of 0.2-0.5mm.

[0032] The outer wall of the cable bundle 211 has a merging groove 214, which is an isosceles trapezoid. The inner ring wire 111 and the outer ring wire 112 are located within the merging groove 214. The trapezoidal angle of the merging groove 214 is 60°-75°, the groove depth is 1.2-1.5 times the wire diameter, and the groove width is 1.5-2 times the wire diameter. By clamping the cable bundle 211, the grooved part of the cable bundle 211 tightly wraps the inner ring wire 111 and the outer ring wire 112. Four sets of merging grooves 214 are arranged in a cross shape on the outer wall of the cable bundle 211.

[0033] Fins 213 are evenly distributed around the outer wall of the connecting plate 212. The fins 213 are fixedly installed on the outer wall of the connecting plate 212. There are 6-12 fins 213, with a height of 5-10mm and a thickness of 1-2mm. The material is the same as that of the connecting plate 212, and the surface is anodized.

[0034] Recommendations for the production of wire body

[0035] Conductor stranding: The inner loop wires 111 and outer loop wires 112 must be stranded around the fiber bundle 117 in a specific number (6 inner loop wires and 12 outer loop wires) and arrangement. This requires high precision in the stranding equipment, necessitating precise control of parameters such as stranding pitch and tension to ensure a stable and uniform stranded structure. Inconsistent stranding pitch may affect the flexibility and mechanical properties of the wire, and may also impact its conductivity.

[0036] Shielding and insulation layer covering: The inner insulation layer 113, inner shielding layer 114, outer shielding layer 115, and outer sheath 116 are covered sequentially. The covering process and requirements for each material are different. For example, the wrapping of the aluminum foil shielding layer requires careful control of the overlap width and tension to avoid wrinkles, gaps, and other problems, otherwise the shielding effect will be affected. The copper wire braided shielding layer has strict requirements for the control of the braiding density, requiring professional braiding equipment and skilled operators to ensure shielding efficiency.

[0037] Material property matching: The materials used, such as fiber bundles, silver-plated copper wires, and various insulating and shielding materials, need to be compatible in terms of high-temperature resistance and mechanical properties. This places high demands on material selection and pretreatment. If the thermal expansion coefficients of the materials differ too much, structural damage may occur under high-temperature conditions.

[0038] Production recommendations for heat dissipation connection mechanisms

[0039] Cable Bundle Machining: The merging grooves 214 on the outer wall of the cable bundle 211 need to be machined into isosceles trapezoids with four sets of cross-shaped grooves. This requires high machining accuracy and necessitates the use of precision machining equipment, such as CNC milling machines or machining centers, to ensure the dimensional and positional accuracy of the merging grooves. Furthermore, the connection method between the cable bundle and the connecting plate (integral molding or welding) also presents certain challenges. Integral molding requires high-precision molds and suitable molding processes, while welding requires careful control of welding parameters to ensure connection strength and conductivity.

[0040] Fin installation: Fins 213 are installed on the outer wall of the connecting plate 212. It is necessary to ensure the accuracy of the fin distribution around the plate and the connection strength between the fins and the connecting plate. Brazing, crimping and other methods can be used, but each method has its own process difficulties. For example, brazing requires controlling the amount of brazing filler metal and the welding temperature to ensure the welding quality.

[0041] The connecting plate 212 has a mounting hole in the center and the inner wall of the mounting hole is threaded. A stress buffer ring is provided at the connection between the cable bundle 211 and the connecting plate 212. The outer surface of the outer sheath 116 is provided with a high temperature resistant marking layer. Thermally conductive insulating glue is filled between the fiber bundle 117 and the inner ring wire 111. The inner wall of the cable bundle 211 is coated with an anti-oxidation coating.

[0042] Working principle: The main body of the wire 100 transmits and protects: the fiber bundle 117 serves as the central tensile core, bearing the tensile force of the wire and preventing the wire from breaking; the inner ring wires 111 and the outer ring wires 112 are twisted in layers to form a conductive path for transmitting electrical signals; the inner insulation layer 113 wraps the wires and fiber bundles 117, isolating the conductive part from the outside; the inner shielding layer 114 (aluminum foil) reflects and attenuates high-frequency electromagnetic interference, and the outer shielding layer 115 (copper wire braid) absorbs and shields low-frequency interference, providing double-layer protection to ensure signal purity; the outer sheath 116 is the outermost layer, resisting external mechanical and chemical corrosion and adapting to high-temperature environments.

[0043] Heat dissipation connection mechanism 200 connection and heat dissipation: During installation, the inner ring wire 111 and the outer ring wire 112 are embedded into the merging groove 214 of the wire bundle 211. The isosceles trapezoidal structure of the merging groove 214 restricts the movement of the wires, so that the wires are tightly arranged at the joint and the contact resistance is reduced. When the electrical signal is transmitted, the heat generated at the joint is conducted to the connecting plate 212 through the wire bundle 211, and then comes into contact with the air through the fins 213. The heat is quickly dissipated by heat convection to maintain the low temperature of the joint and ensure the stability of the electrical connection.

[0044] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-temperature resistant small-section wire, characterized in that, include The wire body includes a heat-resistant wire, a fiber bundle is disposed in the middle of the heat-resistant wire, an inner loop wire and an outer loop wire are wrapped around the fiber bundle, and an outer sheath is wrapped around the inner loop wire and the outer loop wire. A heat dissipation connection mechanism includes a heat dissipation connector, which includes a wire bundle, which is limitedly connected to the inner and outer ring wires, and a connecting plate is fixedly connected to the end of the wire bundle.

2. The high-temperature resistant small-section wire as described in claim 1, characterized in that: The inner loop filaments are provided in six units, which are distributed around the outside of the fiber bundle.

3. The high-temperature resistant small-section wire as described in claim 2, characterized in that: The outer ring wires are provided with 12, and the 12 outer ring wires are distributed around the outside of the inner ring wires.

4. The high-temperature resistant small-section wire as described in claim 3, characterized in that: The outer loop wire is wrapped with an inner insulation layer, which is tightly wrapped around the inner loop wire, the outer loop wire, and the fiber bundle.

5. The high-temperature resistant small-section wire as described in claim 4, characterized in that: The inner insulating layer is surrounded by an inner shielding layer, which is an aluminum foil shielding layer.

6. The high-temperature resistant small-section wire as described in claim 5, characterized in that: The outer wall of the inner shielding layer is wrapped with an outer shielding layer, which is a copper wire braided shielding layer.

7. The high-temperature resistant small-section wire as described in claim 6, characterized in that: The outer wall of the outer shielding layer is covered with an outer sheath.

8. The high-temperature resistant small-section wire as described in claim 1, characterized in that: The outer wall of the wire bundle is provided with a merging groove, which is an isosceles trapezoidal shape, and the inner and outer loop wires are located in the merging groove.

9. The high-temperature resistant small-section wire as described in claim 8, characterized in that: The merging slots are arranged in four sets at a cross shape on the outer wall of the cable bundle.

10. The high-temperature resistant small-section wire as described in claim 1, characterized in that: The outer wall of the connecting plate is evenly distributed with fins, and the fins are fixedly installed on the outer wall of the connecting plate.

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