High flexible and high strength copper clad steel automobile wire for commercial vehicle

Abstract

The utility model relates to the technical field of automobile wire and discloses high-soft high-strength copper-clad steel automobile wire for business car, include: conductor unit and insulating sheath, the insulating sheath is covered in the outside of conductor unit, the conductor unit includes inner stranding layer and outer stranding layer, the outer stranding layer concentric stranding constitutes with inner stranding layer, the outer stranding layer is stranding in the outside of inner stranding layer, the inner stranding layer is stranding constitutes by tensile metal wire, the outer stranding layer is stranding constitutes by conducting wire; The insulating sheath includes first insulating layer, metal braid, stress release ring and second insulating layer. The utility model discloses by setting up by tensile metal wire and conducting wire respectively stranding constitutes and concentric stranding's inner, outer stranding layer, guarantees conductivity and promotes tensile strength and flexibility, solves the problem that pure copper conductor wire is easy to break, reduces weight and improves efficiency, also overcomes the problem of aluminum conductor space occupation, and the outer layer insulating sheath structure realizes excellent insulation and mechanical protection, reduces the risk of breakage.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring technology, specifically to high-flexibility, high-strength copper-clad steel automotive wiring for commercial vehicles. Background Technology

[0002] As the automotive industry moves towards electrification and intelligentization, the reliability requirements for electrical systems in commercial vehicles have significantly increased. While traditional pure copper wires possess good conductivity, they have significant drawbacks in applications such as large commercial vehicles, engineering vehicles, and mining vehicles: firstly, the high density of pure copper increases the weight of the entire vehicle's wiring harness, affecting fuel economy and load-bearing capacity; secondly, frequent bending conditions can easily lead to metal fatigue, increasing the risk of wire breakage. Furthermore, the cost of pure copper wires accounts for a disproportionately high percentage of the total vehicle wiring harness cost, hindering the vehicle's economic efficiency.

[0003] In existing technologies, some solutions use aluminum conductors instead of copper, but aluminum has lower conductivity than copper, requiring a larger conductor cross-section to meet current-carrying requirements, which exacerbates the space occupation problem. Another solution improves performance by optimizing the purity of copper, but this is costly. Therefore, a high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles has been proposed. Utility Model Content

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this utility model provides a high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles, thereby solving the problems mentioned in the background section.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, this utility model provides the following technical solution: a high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles, comprising:

[0008] The conductor unit and the insulating sheath, wherein the insulating sheath covers the outside of the conductor unit, the conductor unit includes an inner stranded layer and an outer stranded layer, the outer stranded layer and the inner stranded layer are concentrically stranded, the outer stranded layer is stranded outside the inner stranded layer, the inner stranded layer is made of tensile metal wire stranded together, and the outer stranded layer is made of conductive metal wire stranded together.

[0009] The insulating sheath includes a first insulating layer, a metal braided mesh, a stress-relieving ring, and a second insulating layer.

[0010] Preferably, the outer stranded layer and the inner stranded layer are stranded in opposite directions, and the pitch of the inner stranded layer is twice the pitch of the outer stranded layer.

[0011] Preferably, the diameter ratio of the tensile metal wire to the conductive metal wire is 1:1.5.

[0012] Preferably, the metal braided mesh is disposed outside the first insulating layer, and the mesh density of the metal braided mesh is not less than 80%.

[0013] Preferably, the stress relief ring is disposed on the outside of the metal braided mesh, and the braiding angle of the metal braided mesh is 45°±5°.

[0014] Preferably, the second insulating layer is disposed outside the stress relief ring, and the stress relief ring has a corrugated structure, the height difference between the crests and troughs of which is 20%-30% of the thickness of the insulating sheath.

[0015] (III) Beneficial Effects

[0016] Compared with the prior art, this utility model provides a high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles, which has the following advantages:

[0017] This invention achieves both good conductivity of the conductor unit and significantly improved tensile strength and flexibility by setting an inner stranded layer composed of tensile metal wires and an outer stranded layer composed of conductive metal wires, with the two stranded concentrically. This effectively solves the problem of metal fatigue fracture of traditional pure copper wires under frequent bending conditions, while reducing the weight of the wiring harness, improving the fuel economy and load capacity of the vehicle, and overcoming the problem of increased space occupation caused by the need to increase the cross-section of aluminum wires to meet current carrying requirements.

[0018] The outer insulating sheath design adopts a structure that includes a first insulating layer, a metal braided mesh, a stress relief ring, and a second insulating layer, achieving excellent insulation performance and mechanical protection. The metal braided mesh enhances the sheath's anti-interference and mechanical strength, while the stress relief ring effectively releases stress, preventing the wire harness from being damaged due to stress concentration and reducing the risk of wire breakage.

[0019] In addition, this design, while ensuring performance, also reduces costs and improves the vehicle's economy compared to solutions that optimize copper purity. Attached Figure Description

[0020] Figure 1 This is a perspective view of the overall structure of this utility model;

[0021] Figure 2 This is a cross-sectional view of the insulating sheath structure of this utility model;

[0022] Figure 3 This is a schematic diagram of the twisted configuration of a single high-strength metal wire and a single conductive metal wire according to this utility model.

[0023] In the diagram: 1. Tensile metal wire; 2. Conductive metal wire; 3. First insulating layer; 4. Metal braided mesh; 5. Stress relief ring; 6. Second insulating layer. Detailed Implementation

[0024] 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.

[0025] This utility model provides a technical solution: a high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles. Please refer to [link / reference needed]. Figure 1 , Figure 2 and Figure 3 ,include:

[0026] The conductor unit and the insulating sheath are covered by the conductor unit. The conductor unit includes an inner stranded layer and an outer stranded layer. The outer stranded layer is concentrically stranded with the inner stranded layer. The outer stranded layer is stranded outside the inner stranded layer. The inner stranded layer is made of tensile metal wire 1 stranded together, and the outer stranded layer is made of conductive metal wire 2 stranded together.

[0027] The insulating sheath includes a first insulating layer 3, a metal braided mesh 4, a stress relief ring 5, and a second insulating layer 6.

[0028] Please see Figure 1 and Figure 3 The outer stranded layer and the inner stranded layer are stranded in opposite directions, and the pitch of the inner stranded layer is twice that of the outer stranded layer.

[0029] Please see Figure 1 and Figure 3 The diameter ratio of the tensile metal wire 1 to the conductive metal wire 2 is 1:1.5.

[0030] Please see Figure 1 and Figure 2 The metal woven mesh 4 is disposed outside the first insulating layer 3, and the mesh density of the metal woven mesh 4 is not less than 80%.

[0031] Please see Figure 1 and Figure 2 The stress relief ring 5 is set on the outside of the metal braided mesh 4, and the braiding angle of the metal braided mesh 4 is 45°±5°.

[0032] Please see Figure 1 and Figure 2 The second insulating layer 6 is disposed outside the stress relief ring 5. The stress relief ring 5 has a corrugated structure, and the height difference between its crest and trough is 20%-30% of the thickness of the insulating sheath.

[0033] This solution: The inner stranded layer is made of tensile metal wire 1 twisted together. The tensile metal wire 1 is made of copper-clad steel. This material combines the conductivity of copper and the tensile strength of steel, which not only ensures good conductivity, but also enhances the tensile strength of the cable.

[0034] The outer stranded layer is composed of conductive metal wires 2 twisted together. The conductive metal wires 2 are also made of copper-clad steel to achieve good conductivity.

[0035] Both the first insulating layer 3 and the second insulating layer 6 are made of high-performance polyvinyl chloride material, which has good insulation performance and chemical corrosion resistance. The first insulating layer 3 is tightly attached to the outside of the conductor unit, providing the first layer of insulation protection for the conductor unit and preventing current leakage and external interference.

[0036] The metal braided mesh 4 is set outside the first insulation layer 3 and is made of tin-plated copper wire. The high-density braided structure can effectively shield external electromagnetic interference and ensure that the automotive wiring harness works stably in a complex electromagnetic environment.

[0037] The stress relief ring 5 is located on the outside of the metal braided mesh 4 and has a corrugated structure. The corrugated structure can act as a buffer when the cable is bent, effectively releasing stress, preventing the cable from being damaged due to stress concentration, and extending the service life of the cable.

[0038] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0039] Although embodiments of the present 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 present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles, characterized in that: include: Conductor unit and insulating sheath, the insulating sheath covering the outside of conductor unit, conductor unit including inner stranded layer and outer stranded layer, the outer stranded layer and inner stranded layer are concentrically stranded, the outer stranded layer is stranded outside the inner stranded layer, the inner stranded layer is stranded from tensile metal wire (1), and the outer stranded layer is stranded from conductive metal wire (2). The insulating sheath includes a first insulating layer (3), a metal braided mesh (4), a stress relief ring (5), and a second insulating layer (6).

2. The high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles according to claim 1, characterized in that: The outer stranded layer and the inner stranded layer are stranded in opposite directions, and the pitch of the inner stranded layer is twice the pitch of the outer stranded layer.

3. The high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles according to claim 2, characterized in that: The diameter ratio of the tensile metal wire (1) to the conductive metal wire (2) is 1:1.

5.

4. The high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles according to claim 1, characterized in that: The metal woven mesh (4) is disposed outside the first insulating layer (3).

5. The high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles according to claim 4, characterized in that: The stress relief ring (5) is disposed on the outside of the metal braided mesh (4).

6. The high-flexibility, high-strength copper-clad steel automotive wire for commercial vehicles according to claim 5, characterized in that: The second insulating layer (6) is disposed on the outside of the stress relief ring (5).

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