A multi-core anti-interference self-shielding high-wear-resistant multifunctional cable for new energy vehicles

Abstract

A new energy automobile is with multi-core anti-interference self-shielding high wear-resistant multifunctional cable belongs to the technical field of automobile wiring harness, including several conductors 7 twisted by metal wire, the conductor 7 is covered by insulating layer 8 and first sheath layer 9 in turn, first sheath layer 9 and reinforcing strip 1 are twisted and covered by isolation layer 3, the diameter of first sheath layer 9 and reinforcing strip 1 is equal, the gap between first sheath layer 9, reinforcing strip 1 and isolation layer 3 is filled by filling layer 2, isolation layer 3 is covered by heat-resistant layer 4, braided layer 5 and second sheath layer 6 in turn, the reinforcing strip 1 and first sheath layer 9 are twisted to improve the mechanical strength and bending resistance of the cable.The utility model discloses the cable core and high molecular weight polyethylene filling strip are twisted, guaranteeing the softness of original conductor, improving bending resistance and keeping conductor flexibility;The synergistic effect of composite layer structure significantly prolongs the service life of the cable under complex working conditions.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring harness technology, and in particular to a multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles. Background Technology

[0002] In recent years, the complex operating environment of new energy vehicles (such as confined spaces, high-frequency vibration, high temperatures, and repeated bending) has placed higher demands on cable performance. Existing technologies for new energy cables exhibit the following significant drawbacks: First, the conductor structure is simple, using pure copper or tin-plated copper single-wire designs, which are prone to breakage under longitudinal tensile force during frequent bending, leading to power transmission interruptions. Second, anti-interference capabilities are insufficient; the single-core layout and weak shielding design make signal transmission susceptible to electromagnetic interference within the vehicle, causing signal distortion or even control failure. Third, the materials have poor weather resistance; the single sheath layer lacks sufficient high-temperature resistance and is prone to aging and cracking under long-term high-temperature environments, while the single silicone layer has weak scratch resistance, exacerbating the risk of insulation damage. Fourth, there are structural design contradictions; to meet bending resistance requirements, the number of cores is reduced and the sheath layer thickness is increased, which limits the cable's functional expansion (such as multi-signal integration) and increases costs by approximately 20%-30% due to material redundancy. While existing technologies attempt to improve individual performance indicators through local optimization, they fail to systematically resolve the synergistic contradictions between mechanical strength, electromagnetic shielding, weather resistance, and cost control. This results in inconsistent cable lifespans and significant safety hazards, making it difficult to meet the core requirements of high reliability and long lifespan for new energy vehicles. Utility Model Content

[0003] In order to overcome the above-mentioned technical defects, this utility model provides a multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles, so as to solve at least one technical problem existing in the background art.

[0004] This utility model provides the following technical solution: a multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles, comprising several conductors 7 made of twisted metal wires, wherein the conductors 7 are sequentially covered by an insulation layer 8 and a first sheath layer 9, the first sheath layer 9 and a reinforcing strip 1 are twisted together and then covered by an isolation layer 3, the first sheath layer 9 and the reinforcing strip 1 have the same diameter, the gap between the first sheath layer 9, the reinforcing strip 1 and the isolation layer 3 is filled by a filling layer 2, and the isolation layer 3 is sequentially covered by a silicone layer 4, a braided layer 5 and a second sheath layer 6, wherein the reinforcing strip 1 and the first sheath layer 9 are twisted together to improve the mechanical strength and bending resistance of the cable.

[0005] Furthermore, the metal wire is an oxygen-free copper wire with a purity of 99.99% or higher, the strand-to-diameter ratio of conductor 7 is 64 / 0.11 mm, the outer diameter of the stranded conductor 7 is 0.92 mm, the resistance of conductor 7 is 37.1 Ω / m, the number of oxygen-free copper wires is 7 to 37, and the diameter of a single oxygen-free copper wire ranges from 0.15 to 0.30 mm.

[0006] Furthermore, the insulating layer 8 is made of polymer material through an extrusion process. The outer diameter of the insulating layer 8 ranges from 1.5 to 1.7 mm, the thickness of the insulating layer 8 is greater than or equal to 0.24 mm, the concentricity of the insulating layer 8 is ≥85%, and the twisting pitch of the insulating layer 8 ranges from 20 ± 5 mm.

[0007] Furthermore, several conductors 7 covered with insulation layer 8 are twisted together and then covered with a first sheath layer 9, which is used to enhance mechanical properties.

[0008] Furthermore, the reinforcing strip 1 is made of ultra-high molecular weight polyethylene, and the reinforcing strip 1 is twisted together with the first sheath layer 9 to improve the mechanical strength and bending resistance of the cable.

[0009] Furthermore, the isolation layer 3 includes a polymer film for isolating the materials on both the inner and outer sides of the isolation layer 3.

[0010] Furthermore, the filler layer 2 includes flame-retardant foamed polyurethane to improve the flame-retardant performance of the cable.

[0011] Furthermore, inorganic thermally conductive fillers are provided inside the silicone layer 4.

[0012] Furthermore, the braided layer 5 includes a tinned copper wire braided mesh that enhances the shielding of the cable. The tinned copper wire braided mesh has a wire diameter of 0.12 mm and a braiding density of >80%.

[0013] Furthermore, the second sheath layer 6 comprises polytetrafluoroethylene produced by a semi-extruded process to enhance the cable's abrasion resistance.

[0014] The technical effects and advantages of this utility model are as follows:

[0015] 1. Enhanced mechanical properties: The wire core is twisted with high molecular weight polyethylene filler strips, which improves the bending resistance and maintains the flexibility of the conductor while ensuring the original flexibility of the conductor;

[0016] 2. Multiple protection design: The flame-retardant foamed polyurethane layer improves flame retardancy, the silicone layer inside the braided layer enhances high temperature resistance, high pressure resistance and aging resistance, and the outer sheath forms double protection;

[0017] 3. Functional integration optimization: The innovative structural design supports increasing the number of internal functional wires, expanding the multi-signal transmission capability of a single cable;

[0018] 4. Enhanced durability: The synergistic effect of the composite layer structure significantly extends the service life of cables under complex working conditions. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of this utility model.

[0020] The components are: 1. Reinforcing strip; 2. Filler layer; 3. Insulating layer; 4. Silicone layer; 5. Braided layer; 6. Second sheath layer; 7. Conductor; 8. Insulating layer; 9. First sheath layer. Detailed Implementation

[0021] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. This utility model is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0022] Reference Figure 1 As shown, this utility model provides a multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles, including a conductor 7 made of stranded metal wires. The metal wires include oxygen-free copper wires with a surface tin plating or bare copper, and the purity of the oxygen-free copper wires is above 99.99% to ensure the conductivity of the conductor 7. The conductor 7 adopts a regular stranded structure. The strand / diameter ratio of the conductor 7 is 64 / 0.11 mm, the outer diameter of the stranded conductor 7 is 0.92 mm, and the resistance of the conductor 7 is 37.1 Ω / m.

[0023] The number of oxygen-free copper wires is 7 to 37, and the diameter of a single wire ranges from 0.15 to 0.30 mm.

[0024] The conductor 7 is covered with an insulating layer 8, which is made of a polymer material through an extrusion process. The polymer material includes polypropylene, cross-linked polyethylene copolymer, or silicone rubber. The outer diameter of the insulating layer 8 ranges from 1.5 to 1.7 mm, the thinnest point thickness is 0.24 mm, the concentricity is ≥85%, and the stranding pitch ranges from 20 ± 5 mm.

[0025] Several conductors 7, each covered with an insulating layer 8, are twisted together and then covered with a first sheath layer 9. Figure 1 Two conductors 7, each covered with an insulation layer 8, are shown stranded together with a pitch ratio of 15. The first sheath layer 9 comprises a thermoplastic polyurethane elastomer material to enhance mechanical properties.

[0026] Several first sheath layers 9 are twisted together with several reinforcing strips 1, and the diameter of the reinforcing strips 1 is the same as that of the first sheath layers 9. Figure 1The cable consists of two first sheath layers 9 twisted together with two reinforcing strips 1. The reinforcing strips 1 are made of ultra-high molecular weight polyethylene. The twisting of the reinforcing strips 1 with the first sheath layers 9 improves the cable's mechanical strength and bending resistance. The outer diameter of the reinforcing strips 1 is 2.35 mm.

[0027] The isolation layer 3 covers several first sheath layers 9 and several reinforcing strips 1. Figure 1 The isolation layer 3 is covered by two first sheath layers 9 and two reinforcing strips 1. The isolation layer 3 includes a polymer film to separate the inner and outer materials of the isolation layer 3.

[0028] The gap between the first sheath layer 9, the reinforcing strip 1, and the isolation layer 3 is filled by the filler layer 2. Flame-retardant foamed polyurethane is added to the filler layer 2 to improve the flame-retardant performance of the cable.

[0029] The silicone layer 4 covers the insulating layer 3. The silicone layer 4 is used for heat dissipation. Inorganic thermally conductive filler is set inside the silicone layer 4 to enhance the heat resistance of the cable.

[0030] The braided layer 5 covers the silicone layer 4. The braided layer 5 includes a tinned copper wire braided mesh to enhance the shielding of the cable. The tinned copper wire braided mesh has a wire diameter of 0.12 mm and a braiding density of >80%. The tinned copper wire braided mesh also prevents external vibrations from penetrating the internal structure of the cable and avoids stress on the internal wire cores.

[0031] The second sheath layer 6 covers the braided layer 5. The second sheath layer 6 includes polytetrafluoroethylene (PTFE) produced by a semi-extrusion process to enhance the cable's abrasion resistance. Before the PTFE is extruded, the conductor 7, covered with the insulation layer 8, and the reinforcing strip 1 are laid together and extruded through a die. The outer diameter of the second sheath layer 6 ranges from 9.5 to 1.1 mm, and the sheath thickness ranges from 0.7 mm to 1.0 mm.

[0032] The cable is formed using a de-twisting process with a de-twisting rate of 30%-50% and a cable pitch of 50-60mm, forming a cable core structure.

[0033] It should be understood that, firstly, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship may change.

[0034] Secondly: The accompanying drawings of the embodiments disclosed in this utility model only involve the structures involved in the embodiments disclosed in this utility model. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this utility model can be combined with each other.

[0035] Finally: The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles, comprising several conductors (7) made of twisted metal wires, wherein the conductors (7) are sequentially covered by an insulation layer (8) and a first sheath layer (9), characterized in that: The first sheath layer (9) and the reinforcing strip (1) are twisted together and then covered by the isolation layer (3). The diameters of the first sheath layer (9) and the reinforcing strip (1) are equal. The gap between the first sheath layer (9), the reinforcing strip (1) and the isolation layer (3) is filled by the filling layer (2). The isolation layer (3) is covered by the silicone layer (4), the braided layer (5) and the second sheath layer (6) in sequence. The twisting of the reinforcing strip (1) and the first sheath layer (9) is used to improve the mechanical strength and bending resistance of the cable.

2. The multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 1, characterized in that: The metal wire is an oxygen-free copper wire with a purity of 99.99% or higher. The strand-to-diameter ratio of the conductor (7) is 64 / 0.11 mm, the outer diameter of the stranded conductor (7) is 0.92 mm, the resistance of the conductor (7) is 37.1 Ω / m, the number of oxygen-free copper wires is 7 to 37, and the diameter of a single oxygen-free copper wire is 0.15 to 0.30 mm.

3. The multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 1, characterized in that: The insulating layer (8) is made of polymer material by extrusion process. The outer diameter of the insulating layer (8) is 1.5 to 1.7 mm, the thickness of the insulating layer (8) is greater than or equal to 0.24 mm, the concentricity of the insulating layer (8) is ≥85%, and the twisting pitch of the insulating layer (8) is 20 ± 5 mm.

4. The multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 3, characterized in that: Several conductors (7) covered with insulation layer (8) are twisted together and then covered with first sheath layer (9), which is used to enhance mechanical properties.

5. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 4, characterized in that: The reinforcing strip (1) is made of ultra-high molecular weight polyethylene. The reinforcing strip (1) is twisted with the first sheath layer (9) to improve the mechanical strength and bending resistance of the cable.

6. The multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 5, characterized in that: The isolation layer (3) includes a polymer film used to isolate the materials on the inside and outside sides.

7. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 6, characterized in that: Flame-retardant polyurethane foam is provided in the filling layer (2) to improve the flame-retardant performance of the cable.

8. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 7, characterized in that: Inorganic thermally conductive filler is provided inside the silicone layer (4).

9. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 8, characterized in that: The braided layer (5) includes a tinned copper wire braided mesh that can enhance the shielding of the cable. The tinned copper wire braided mesh has a wire diameter of 0.12 mm and a braiding density of >80%.

10. A multi-core anti-interference self-shielded high wear-resistant multifunctional cable for new energy vehicles according to claim 1, characterized in that: The second sheath layer (6) includes polytetrafluoroethylene made by a semi-extrusion process to enhance the cable's abrasion resistance.

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